ADJUSTABLE RELOADABLE CABLE REEL

Abstract

A reel for storing a cable coil includes first and second facing flanges. First, second and third cylindrical rods define a hub and have first ends attached to the first flange and opposite, second ends extending through holes formed in the second flange. A guidepost has a first end attached to the first flange and a second end passing through an opening in the second flange. A lock set allows a distance between the first and second flanges to be selected. Attachment positions of the first ends of the cylindrical rods to the first flange are manually or automatically adjustable to change a diameter of the hub. Bushings within end openings of the guidepost control the rotation payout speed of the reel, and a parking park feature is provided at the second end of the guidepost to block rotation of the reel.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a cable reel, and a cable reel in combination with a coil of cable. More particularly, the present invention relates to a cable reel wherein a hub diameter may be adjusted to accommodate variance of inner diameters of coils, and a spacing between a first flange and a second flange may be adjusted to accommodate different thicknesses of coils, e.g., lengths of cable.

2. Description of the Related Art

Reels to hold a coil of cable are known in the prior art, and can be found in U.S. Pat. Nos. 1,674,709; 1,831,848; 3,326,495; 3,432,113; 3,565,363; 3,815,842; 3,830,445; 3,840,198; 4,009,842; 4,124,176; 4,867,391; 4,903,913; 5,261,625; 5,344,094; 6,145,780; 6,234,421; 6,655,627; 7,121,501; 7,510,138; 8,727,262; 9,637,343; 9,695,008; 9,862,566; 9,873,588; 10,589,957; and 10,611,598, as well as in U.S. Published Applications 2004/0026561; 2005/0045759; 2010/0051738 and 2014/0312159, each of which is herein incorporated by reference.

SUMMARY OF THE INVENTION

The Applicant has discovered drawbacks with the reels of the prior art. It is an object of the present invention improve upon the designs of the prior art.

It is known in the prior art that a variance in the inner diameter of coils of cable may exist. If the inner diameter of the coil of cable is even slightly larger than an outer diameter of the hub of the reel, the coil of cable may free spin on the hub, rather than having the entire reel rotating about an axis of rotation. This is undesirable, as the reel may include a frictional drag or brake feature to slow or stop deployment of the cable. If the cable coil can free spin on the hub of the reel, the frictional drag or brake will be ineffective. It is an object of the invention to provide a hub which can be manually expanded and contracted in diameter so as to accommodate slight variations in the inner diameter of a coil of cable.

It is also known in the prior art that a variance in a longitudinal thickness of a coil of cable may exist, due to coils of different lengths of cable. A “radial” thickness of a coil of cable may be viewed as a distance between the inner diameter of the coil and the outer diameter of the coil, whereas the “longitudinal” thickness of a coil is the distance between a first side of the coil and a second side of the coil. The longitudinal thickness of a coil is related to the number of winding of the coil, which form the first layer of the inner diameter and hence may relate to an overall length of the cable forming the coil.

In order to accommodate coils of cables with different lengths, a spacing between the first and second flanges must be adjustable. There are various designs to accommodate this spacing in the prior art. However, the present invention provides a unique system, whereby the second flange may be removed from the hub to facilitate loading of a new coil of cable upon the hub, and improvements are provided to easily reassemble of the second flange onto the hub and to lock the second flange in various positions along the hub to vary a distance between the first and second flanges.

It is also an object of the present invention to provide an improved friction drag system and an improved parking brake system to slow and halt rotation of the reel, respectively.

Hence, it is an overall object of the present invention to improve upon the flange spacing adjustments and the hub sizing adjustments of the prior art by providing a structure which allows the flange spacing and hub diameter to be adjusted in an easier manner, and/or allows for a cheaper/lower cost construction of the reel.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limits of the present invention, and wherein:

FIG. 1 is an exploded left-side perspective view of a cable reel, in accordance with the present invention;

FIG. 2 is an exploded right-side perspective view of the cable reel of FIG. 1;

FIG. 3 is a left-side perspective view of the cable reel of FIG. 1 in an assembled state with a maximum distance set between first and second flanges;

FIG. 4 is a cross sectional view taken along line IV—IV in FIG. 3;

FIG. 5 is a right-side perspective view of the cable reel of FIG. 3;

FIG. 6 is a left-side perspective view of the cable reel, similar to FIG. 3, but showing a coil of cable loaded thereon;

FIG. 7 is a right-side perspective view of the cable reel of FIG. 6;

FIG. 8 is a left-side perspective view of a cable reel with the second flange removed and a short coil of cable loaded onto the first flange;

FIG. 9 shows the cable reel of FIG. 8 with the second flange installed to capture the coil of cable between the first and second flanges, with a medium distance set between the first and second flanges;

FIG. 10 is right-side perspective view of the cable reel of FIG. 9 with the coil of cable removed;

FIG. 11 is a cross sectional view taken along line XI—XI in the FIG. 10;

FIG. 12 is a left-side perspective view of an alternative embodiment for an elongated member to form a part of a hub;

FIG. 13 is a left-side perspective view of a cable reel having automatically adjusting elongated members to vary a diameter of a hub;

FIG. 14 is a left-side perspective view of the cable reel of FIG. 13 with the second flange removed and the elongated members forming the hub with a maximum diameter;

FIG. 15 is a left-side perspective view of the cable reel, similar to FIG. 14, but illustrating the elongated members forming the hub with a minimum diameter; and

FIG. 16 is a top view of the cable reel of FIG. 14 illustrating the maximum and minimum potential hub diameters.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. Broken lines illustrate optional features or operations unless specified otherwise.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “lateral”, “left”, “right” and 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. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the descriptors of relative spatial relationships used herein interpreted accordingly.

FIGS. 1 and 2 depict left-side and right-side perspective views of the unassembled parts to form a reel 11 for storing a coil of cable 13, in accordance with the present invention. The reel 11 includes a first generally circular flange 15 having a first side 17 and a second side 19. In the depicted embodiment, an outer rim of the first flange 15 is circular, and has a diameter of about 20 to 60 centimeter, such as 30 to 50 centimeters, more preferably about 35 to 45 centimeters. Although a circular rim is shown the rim may have undulations to reduce its weight.

Each of first, second and third elongated members 21, 23 and 25 has a first end 27, 29 and 31, respectively, which is attached to the first flange 15. Opposite, second ends 33, 35 and 37 of the first, second and third elongated members 21, 23 and 25, respectively, extend away from the first side 17 of the first flange 15. The second ends 33, 35 and 37 preferably include a conical shape.

A spacing between the first, second and third elongated members 21, 23 and 25 defines a diameter of a hub of the reel 11. More specifically, the outermost radial edges of the first, second and third elongated members 21, 23 and 25 relative to a center of the first flange 15 define contact edges for a coil of cable 13 placed upon the hub, and hence define the minimum diameter of the coil of cable 13 which will fit onto the reel 11. To accommodate coils of cable 13 with slightly differing inner diameters, at least one first end 27, 29 or 31 of the first, second or third elongated members 21, 23 or 25 is adjustable in its attachment to the first flange 15. In a preferred embodiment, each first end 27, 29 and 31 of the first, second and third elongated members 21, 23 and 25 is adjustable in its attachment to the first flange 15.

In a preferred embodiment, each of the first, second and third elongated members 21, 23 and 25 is formed as a cylindrical rod. Each of the first ends 27, 29 or 31 of each cylindrical rod includes a first threaded portion in the form of a threaded bore hole 39, 41 or 43, respectively, to accept therein a threaded faster in the form of a threaded bolt 45, 47 or 49, respectively, so as to attached the first ends 27, 29 and 31 of each cylindrical rod to the first flange 15.

The first flange 15 includes first, second and third slots 51, 53 and 55 to receive shaft portions of the threaded bolts 45, 47 and 49. The second side 19 of the first flange 15 includes indentations 57 (best seen in FIG. 5) formed alongside edges of the first, second and third slots 51, 53 and 55 to seat heads of the threaded bolts 45, 47 and 49 at different locations along the first, second and third slots 51, 53 and 55. As the threaded bolts 45, 47 and 49 are tightened, tall elastic washers 38, 40 and 42 are compressed. The elastic washers 38, 40 and 42 perform dual functions. First, the elastic washers 38, 40 and 42 allow the first, second and third elongated members 21, 23 and 25 to tilt relative to the first side 17 of the first flange 15 when placed under lateral pressure, while remaining biased by the resiliency of the elastic washers 38, 40 and 42 to return to a perpendicular orientation relative to the first side 17 of the first flange 15. Second, the elastic washers 38, 40 and 42 act as a lock washer to apply an axial pressure tending to keep the threaded bolts 45, 47 and 49 tight in engagement within the threaded bore holes 39, 41 and 43.

Adjacent to the indentations 57, indicia 59 may be molded into, or protruding from the second side 19 of the first flange 15. The indicia 59 indicates a diameter dimension for the hub e.g., 262 cm, 269 cm, 276 cm, 283 cm and 290 cm. For example, if the first, second and third elongated members 21, 23 and 25 are mounted into the first flange 15 with the heads of the first, second and third threaded bolts 45, 47 and 49 residing within the middle indentations 57 labeled “276 cm,” then the first, second and third elongated members 21, 23 and 25 will engage and snuggly receive a coil of cable 13 having an inner diameter of 276 cm or slightly less than 276 cm with deflection due to the elastic washers 38, 40 and 42. If a coil of cable 13 of a greater diameter, e.g., 282 mm, were placed upon the first, second and third elongated members 21, 23 and 25, the coil of cable 13 will not fit snuggly and will be able to “free spin” about the first, second and third elongated members 21, 23 and 25. If the coil of cable 13 can “free-spin,” a drag system and brake system, to be further explained herein, will not function.

The reel 11 also includes a second generally circular flange 61 having a first side 63 and a second side 65. In the depicted embodiment, an outer rim of the second flange 61 is circular, and has a same diameter as the first flange 15. The first side 63 of the second flange 61 faces the first side 17 of the first flange 15. The second flange 61 includes first, second and third through holes 67, 69 and 71. The second ends 33, 35 and 37 of the first, second and third elongated members 21, 23 and 25 pass through the first, second and third through holes 67, 69 and 71, respectively, so as to reside beyond the second side 65 of the second flange 61 (best seen in FIG. 3).

First, second and third partial or full funnel-shaped attachments 73, 75 and 77 are mounted to or integrally formed with the first side 63 of the second flange 61. As depicted in FIG. 2, partial funnel shapes are employed, and the first, second and third attachments 73, 75 and 77 are integrally molded with the second flange 61. Each of the first, second and third attachments 73, 75 and 77 is located adjacent to the first, second and third through holes 67, 69 and 71, respectively, to guide the second ends 33, 35 and 37 of the first, second and third elongated members 21, 23 and 25 toward and into the first, second and third through holes 67, 69 and 71, respectively.

The combination of the conical shape of the second ends 33, 35 and 37 and the funnel shape of the first, second and third attachments 73, 75 and 77 act to smoothly guide and gradually tilt the first, second and third elongated members 21, 23 and 25 against the biasing forces of the elastic washers 38, 40 and 42. Once the second ends 33, 35 and 37 make contact with the first, second and third attachments 73, 75 and 77, the user can apply downward force on the second side 65 of the second flange 61 toward the first flange 15 (with its second side 19 resting on the ground). The second flange 61 will then side onto the first, second and third elongated members 21, 23 and 25.

To adjust and hold a desired spacing between the first and second flanges 15 and 61, the reel 11 includes a guidepost 79. The guidepost 79 also functions as a point of support to attach the reel 11 to a reel support structure. The guidepost 79 is formed as a generally cylindrical shaft with a first end 81 attached to a central portion of the first flange 15. One potential manner to attach the first end 81 to the first flange 15 would be to provide a base flange 83 integrally formed with the guidepost 79 with threaded boreholes 85 formed or inserted therein. Short fasteners 87 may be passed through the first flange 15 and engaged into the threaded boreholes 85. Of course, other structures may be used to attach the first end 81 of the guidepost 79 to the first flange 15.

A second end 89 of the guidepost 79 passes through a guidepost opening 91 formed in a central portion of the second flange 61. FIGS. 3-7 show the second end 89 of the guidepost 79 residing approximately flush with, e.g., in a same plane as, the second side 65 of the second flange 61. FIGS. 9-11 show the second end 89 of the guidepost 79 extending beyond the second side 65 of the second flange 61.

A lock set includes a first part 93 formed along an exterior portion of the guidepost 79 and a second part 95 attached to the second side 65 of the second flange 61 proximate the guidepost opening 91. The lock set allows the second flange 61 to be selective locked to different positions along the guidepost 79, so that a user can set a desired distance between the first and second flanges 15 and 61.

The first part 93 of the lock set may be formed as a guide track 97 with a plurality of locking holes 99. Each locking hole 99 is spaced apart from the other locking holes 99 in a direction from the second end 89 of the guidepost 79 to the first end 81 of the guidepost 79, which is the same direction as a central axis A of the guidepost 79. In the depicted embodiments, ten locking holes 99-1, 99-2, 99-3, ...99-10 are illustrated, meaning that the second flange 61 may be locked into ten different positions relative to the first flange 15.

The second part 95 of the lock set is formed as a collar 101 attached to the second flange 61. The collar 101 may be attached to the second side 65 of the second flange 61 by a plurality of screws 100 engaged into threaded bore holes 102 fixed to the second flange 61. The collar 101 has an inner opening 103 which is larger than a diameter of the guidepost 79. Therefore, the collar 101 may slide over a section of guidepost 79. The collar 101 includes a spring-loaded plunger 105 captured therein. The spring-loaded plunger 105 has a pin 107 biased to extend away from the collar 101 toward the guidepost 79, so as to engage within a user selected locking hole 99. The spring-loaded plunger 105 includes a handle 109 attached to the pin 107 to manually pull the pin 107 away from the guidepost 79 and disengage the pin 107 from the locking hole 99.

When the pin 107 is pull out of the locking hole 99, the collar 101 may be slid along the guidepost 79, as desired. Releasing the handle 109 allows the spring-loaded plunger 105 to bias the pin 107 toward the locking holes 99, so that the pin 107 may snap into and be locked within another locking hole 99 to secure the collar 101 to the guidepost 79. In practice, the second flange 61 is pressed toward the first flange until the coil of cable 13 has its lateral sides engaged by both of the first and second flanges 15 and 61, as show in FIGS. 6 and 7, and the pin is seated into a hole 99 at that position.

If a coil of cable 13A of a shorter length is to be installed upon the reel 11, the second flange 61 is removed, as shown in FIG. 8. The coil of cable 13A is placed upon the hub by encircling the first, second and third elongated members 21, 23 and 25. The conical shape at the second ends 33, 35 and 37 of the first, second and third elongated members 21, 23 and 25 may assist with placing the coil of cable 13A onto the hub. The coil of cable 13A is pressed downward until it engages the first side 17 of the first flange 15.

If the fit is too tight and the coil of cable 13A cannot reach the first side 17 of the first flange 15, the threaded bolts 45, 47 and 49 are removed and relocated into different indentations 57 alongside the edges of the first, second and third slots 51, 53 and 55 to resize the hub. If the fit is too loose and the coil of cable 13A is able to free-spin about the hub, the threaded bolts 45, 47 and 49 are removed and relocated into different indentations 57 alongside the edges of the first, second and third slots 51, 53 and 55 to resize the hub.

After the coil of cable is installed on the first flange 15, the second flange 61 is oriented over the first flange with the first, second and third through holes 67, 69 and 71 generally aligned to the second ends 33, 35 and 37 of the first, second and third elongated members 21, 23 and 25. The handle 109 of the spring-loaded plunger 105 is pulled outwardly (and optionally locked outwardly by features of the spring-loaded plunger 105). The second flange 61 is pressed toward the first flange 15 until it abuts the side of the coil of cable 13A. The handle 109 is released or unlocked and the second flange 61 is pushed toward the first flange 15 or backed slightly away from the first flange 15 until the pin 107 snaps into one of the holes 99.

The resulting reel 11 is depicted in FIG. 9. Note how the second ends 33, 35 and 37 now project well beyond the second side 65 of the second flange 61. FIG. 10 shows the reel 11 of FIG. 9 with the coil of cable 13A removed. Note how the funnel-shaped attachments 73, 75 and 77 have engaged the first, second and third elongated members 21, 23 and 25. This engagement may cause the first, second and third elongated members 21, 23 and 25 to tilt outwardly, via the elastic washers 38, 40 and 42, which will enlarge the hub to better engage the inner diameter of the coil of cable 13.

FIG. 11 is a cross sectional view taken along line XI—XI in FIG. 10. FIG. 11 shows the pin 107 engaged into hole 99-5. FIG. 11 also shows that the guidepost 79 includes a first end opening 111 formed into the first end 81 of the guidepost 79. The first end opening 111 extends into the guidepost 79 in the direction of the second end 89 of the guidepost 79. A second end opening 113 is formed into the second end 89 of the guidepost 79. The second end opening 113 extends into the guidepost 79 in the direction of the first end 81 of the guidepost 79.

A first polymer bushing 115 is received within the first end opening 111. The first polymer bushing 115 includes a first lip 119 extending outside of the first end opening 111 of the guidepost 79. A first o-ring 123 is seated into a first groove formed within the first lip 119

A second polymer bushing 117 is received within the second end opening 113. The second polymer bushing 117 includes a second lip 121 extending outside of the second end opening 113 of the guidepost 79. A second o-ring 125 is seated into a second groove formed within the second lip 121.

The first o-ring 123 generates a frictional force tending to resist rotation of the first lip 119 around a first spindle 127 inserted into the first bushing 115, where the first spindle 127 is part of a supporting structure 120 to hold the reel. Likewise, the second o-ring 125 generates a frictional force tending to resist rotation of the second lip 121 around a second spindle 129 inserted into the second bushing 117. The first and second bushings 115 and 117 control a rotation speed of the first and second end openings 111 and 113 of the guidepost 79 about the first and second spindles 127 and 129 based upon a pressure exerted by the first and second spindles 127 and 129 against the first and second bushings 115 and 117.

The supporting structure 120 holding the first and second spindles 127 and 129 has adjustment means, e.g., a screw threaded member, to allow a user to adjust the spacing between the first and second spindles 127 and 129. As the first and second spindles 127 and 129 are moved closer together, the first and second o-rings 123 and 125 are compressed, as the first and second lips 119 and 121 are pressed against the guidepost 79, and the first and second bushings 115 and 117 may also be expanded within the first and second end openings 111 and 113. Each of these actions tends to place a drag on the rotation of the reel 11, so that payoff of the coil of cable 13 or 13A is less easy. Drag on the cable rotation is desirable so that cable does not continue to pay off of the reel 11 after a pulling force on the cable stops.

As best seen in FIG. 4, the reel 11 also includes a parking brake 131 having a first feature, in the form of a through hole 133, attached to the second end 89 of the guidepost 79. The through hole 133 can lock into engagement with a second feature, such as a retractable pin 135, attached to the supporting structure 120 for the reel 11. Rotation of the reel 11 relative to the supporting structure 120 is blocked when the first feature, e.g. the through hole 131, of the parking brake 131 is lock to the second feature, e.g., the retractable pin 135.

In a preferred embodiment as best seen in FIGS. 8 and 9, the parking brake 131 includes two through holes 133 and 133A formed within a parking brake plate 137 attached to the second end 89 of the guidepost 79. The first and second parking brake through holes 133 and 133A are formed in the parking brake plate 137 on radially opposite sides of the guidepost 79.

In the depicted embodiment of FIGS. 1-11, the first, second and third elongated members 21, 23 and 25 are formed as metal, cylindrical rods. However, other configurations may be used. For example, FIG. 12 shows an alternative first elongated member 21A, which may be formed of a polymer. One side of the alternative first elongated member 21A may include a surface 22 with a curved radius to match a radius of curvature of the inner layer of the coil of cable 13 or 13A. The second end 33A includes a conical shape to help guide the alternative first elongated member 21A in the first through hole 67. The first end 27A of the alternative first elongated member 21A includes a threaded stud 39A, which can pass through the elastic washer 38 and attach to a threaded fastener, e.g., a nut 45A. The nut 45A would be seated into one of the indentations 57 on the second side 19 of the first flange 15.

Although the depicted embodiment of FIGS. 1-11 has illustrated three elongated members 21, 23 and 25, more elongated members may be included, such as four, five, six or seven. Of course, additional through holes 67, 69 and 71 would be added to the second flange 61 to accommodate the added elongated members. For example, in the embodiment of FIGS. 13-16, six elongated members are shown.

FIG. 13 is a left-side perspective view of a cable reel 211 having automatically adjusting first, second, third, fourth, fifth and sixth elongated members 213, 215, 217, 219, 221 and 223 to vary a diameter of a hub. The reel 211 includes a first flange 225 having a first side 227 and an opposite, second side. A plurality of arcuate first slots 229, 231, 233, 235, 237 and 239 are formed within the first side 227 of the first flange 225 and preferably pass through to the second side of the first flange 225. Each slot of the plurality of arcuate first slots 229, 231, 233, 235, 237 and 239 has a first end FE closer to a center of the first flange 222 than a second end SE.

A second flange 241 has a first side and an opposite, second side 243. The first side of the second flange 241 faces to the first side 227 of the first flange 225. A plurality of arcuate second slots 245, 247, 249, 251, 253 and 255 are formed within the first side of the second flange 241 and preferably pass through to the second side 243 of the second flange 241. Each slot of the plurality of arcuate second slots 245, 247, 249, 251, 253 and 255 has a first end FE closer to a center of the second flange 241 than a second end SE.

Each of the first, second, third, fourth, fifth and sixth elongated members 213, 215, 217, 219, 221 and 223 has a first end EF. The first end EF either resides within or passes through one of the plurality of arcuate first slots 229, 231, 233, 235, 237 and 239. If the plurality of arcuate first slots 229, 231, 233, 235, 237 and 239 pass entirely through the first flange 225, the first ends EF of the first, second, third, fourth, fifth and sixth elongated members 213, 215, 217, 219, 221 and 223 pass entirely through the plurality of arcuate first slots 229, 231, 233, 235, 237 and 239 to reside beyond the second side of the first flange 225.

Each of the first, second, third, fourth, fifth and sixth elongated members 213, 215, 217, 219, 221 and 223 has an opposite, second end ES. The second ends ES reside within, or more preferably passes through one of the plurality of arcuate second slots 245, 247, 249, 251, 253 and 255 formed in the second flange 241. As with the embodiment of FIGS. 1-12, each of the plurality of elongated members 213, 215, 217, 219, 221 and 223 has a surface serving as a hub for a coil of cable 31 or 31A placed between the first and second flanges 225 and 241.

At least one biasing member causes the plurality of elongated members 213, 215, 217, 219, 221 and 223 to assume positions within the pluralities of arcuate first and second slots 229, 231, 233, 235, 237, 239, 245, 247, 249, 251, 253 and 255 so as to bear against the second ends SE of the arcuate first and second slots 229, 231, 233, 235, 237, 239, 245, 247, 249, 251, 253 and 255. The biasing members may include first, second, third, fourth, fifth and sixth actuating arms 257, 259, 261, 263, 265 and 267, with each arm having a first end P1 pivotally attached to the first flange 225 and a second end F1 fixed to one of the first, second, third, fourth, fifth and sixth elongated members 213, 215, 217, 219, 221 and 223, respectively.

The biasing members may take the form of a plurality of springs, such as first, second, third, fourth, fifth and sixth springs 269, 271, 273, 275, 277 and 279. Each spring having a first end attached to the first flange 225 and a second end attached to one of the plurality of actuating arms 257, 259, 261, 263, 265 and 267. The plurality of springs 269, 271, 273, 275, 277 and 279 bias the plurality of actuating arms 257, 259, 261, 263, 265 and 267 to cause the plurality of elongated members 213, 215, 217, 219, 221 and 223 to assume positions in abutment with the second ends SE of the pluralities of arcuate first and second slots 229, 231, 233, 235, 237, 239, 245, 247, 249, 251, 253 and 255.

As best seen in FIG. 16, when the second flange 241 is removed, the plurality of elongated members 213, 215, 217, 219, 221 and 223 are exposed and ready to accept a coil of cable 13 or 13A. The springs 269, 271, 273, 275, 277 and 279 bias the elongated members 213, 215, 217, 219, 221 and 223 to engage the second ends SE of the acuate first slots 229, 231, 233, 235, 237 and 239. In this configuration, the hub is at its maximum diameter D1, which may be a fix amount, such as 295 cm or 300 cm.

Preferably, the coil of cable 13 being inserted onto the hub has a smaller inner diameter. The technician hooks the inner diameter of the coil of cable 13 over several of the elongated members, e.g., 213, 215 and 217, and pulls them toward the center of the first flange 225, which elongates the springs, e.g., 269, 271 and 273, associated with the hooked elongated members and allows the remaining portions of the inner diameter of the coil of cable 13 to be hooked over the remaining elongated members, e.g., 219, 221 and 223. The coil of cable 13 is then pressed down onto the first side 227 of the flange 225. This action equalizes the spring tensions as the hub assumes the same diameter as the inner diameter of the coil of cable 13. D2 represents the minimum diameter of the hub, where the elongated members 213, 215, 217, 219, 221 and 223 are in abutment with the first ends FE of the acuate first slots 229, 231, 233, 235, 237 and 239. D2 may be set at a value like 250 cm or 260 cm.

The embodiment of FIGS. 13-16 also illustrate an alternative guidepost 79A. The alternative guidepost 79A is attached to the first flange 225 and extends away from the first side 227 of the first flange 225. The alternative guidepost 79A is attached to the second flange 241 to hold the second flange 241 at a user selected, set distance from the first flange 225. The alternative guidepost 79A is a central shaft attached to a center of the first flange 225 and passing through a central guidepost opening within the second flange 241.

An alternative lock set is attached to the alternative guidepost 79A and to the second flange 241. The alternative lock set may be manually actuated to engage and lock the second flange 241 to the alternative guidepost 79A and disengage the second flange 241 from the alternative guidepost 79A, so that the second flange 241 may be slid along the alternative guidepost 79A to a desired position and then fixed to the alternative guidepost 79A by actuating the lock set.

The second part of the lock set may include a spring-loaded collar 281 attached to the second flange 241, which is biased to frictionally engage with a first part in the form of ribbed rings 283 formed along an outer surface of the alternative guidepost 79A. The spring-loaded collar 281 being releasable by finger pressure to allow the spring-loaded collar 281 to slide along the alternative guidepost 79A until the finger pressure is removed. As the spring-loaded collar 281 slides downward along the alternative guidepost 79A toward the first flange 225, the second ends ES of the plurality of elongated members 213, 215, 217, 219, 221 and 223 extend further through the plurality of arcuate second slots 245, 247, 249, 251, 253 and 255 and further away from the second side 243 of the second flange 241.

The spring-loaded collar 281 will be described generally, herein. However, the collar 281 is commercially available. One example of the collar 281 is sold by the McMaster Company as part number 6168K510 and called a “Quick Connect One-Piece Shaft Collar.” More details about the collar 281 can be understood with reference to the commercially available products.

The collar 281 has an inner opening 285 defined by a friction bushing, which may be formed of a plastic material or other material that creates friction. The bushing is slightly larger than a diameter of the cylindrical outer surface of the alternative guidepost 79A in a first state and may be deformed or aligned to be slightly less than a diameter of the cylindrical outer surface of the alternative guidepost 79A in a second state, such that the collar 281 may slide over a section of the alternative guidepost 79A when the bushing is in the first state.

A lock is attached to the collar 281. In a first embodiment of the collar 281, the lock is a cylindrical ring 287 attached to and spaced from a cylindrical main portion 289. The ring 287 can be manually moved from a first position relative to the main portion 289 against a biasing force to a second portion slightly spaced from the main portion 289 by finger pressure. The ring 287 assumes the first position relative to the main portion 289 whenever the lock is manually released, due to the biasing force.

The collar 281 and the second flange 241 may be adjusted in its position along the alternative guidepost 79A when the lock is in the second position. The collar 281 is locked in position along the alternative guidepost 79A when the lock is in the first position. In other words, manually moving and holding the ring 287 in a displaced condition relative to the main portion 289 causes the bushing of the collar 281 to frictionally disengage the alternative guidepost 79A. Releasing the ring 287 causes the ring 287 to assume its initial position relative to the main portion 289, which causes the inner surface of the bushing to frictionally engage the alternative guidepost 79A and fix the position of the collar 289 relative to the alternative guidepost 79A.

In a preferred embodiment, the first flange 15 or 225 and the second flange 61 or 241 are formed of a sturdy plastic, e.g., HDPE, or a lightweight metal or alloy, and the guidepost 79 or 79A is formed of a sturdy plastic, e.g., HDPE, or a lightweight metal or alloy, e.g., aluminum or stainless steel.

The reels 11 and 211 of the present invention accommodate a variance in the inner diameter of the coil of cable 13 or 13A and prevent “free-spinning” of the coil of cable 13 or 13A. The reels 11 and 211 of the present invention also accommodate coils of cable 13 or 13A having very different longitudinal thicknesses, e.g., side-to-side dimensions, so that both short and long cables can be held by the reels 11 and 211.

The reels 11 and 211 of the present invention have been illustrated as being supported by two spindles, which enter first and second end openings 111 and 113 of the guidepost 79 or 79A. Alternatively, the reels 11 and 211 of the present invention may be supported for rotation by a full-length axle passing completely through the inner opening within the guidepost 79 or 79A.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.

Claims

1. A reel for storing a coil of cable comprising: a first generally circular flange having a first side and a second side;first, second and third elongated members, each elongated member having a first end attached to said first flange and an opposite, second end extended away from said first side of said first flange, a spacing between said first, second and third elongated members defining a diameter of a hub;a second generally circular flange having a first side and a second side, wherein said first side of said second flange faces said first side of said first flange, said second flange including first, second and third through holes, wherein said second ends of said first, second and third elongated members pass through said first, second and third through holes, respectively, so as to reside beyond said second side of said second flange;a guidepost having a first end attached to a central portion of said first flange and a second end passing through a guidepost opening formed in a central portion of said second flange; anda lock set having a first part formed along an exterior portion of said guidepost and a second part attached to said second side of said second flange proximate said guidepost opening, said lock set allowing said second flange to be selective locked to different positions along said guidepost to set a desired distance between said first and second flanges.

2. The reel according to claim 1, wherein at least one first end of said first, second and third elongated members is adjustable in its attachment to said first flange so that the diameter of said hub may be adjusted.

3. The reel according to claim 2, wherein each first end of said first, second and third elongated members is adjustable in its attachment to said first flange.

4. The reel according to claim 3, wherein each first end of said first, second and third elongated members includes a first threaded portion to accept a threaded faster, so as to attached said first ends to said first flange, and further comprising: elastic washers installed between said first ends of said first, second and third elongated members and said first flange, which allow said first, second and third elongated members to tilt relative to said first flange.

5. The reel according to claim 3, wherein each first end of said first, second and third elongated members includes a first threaded portion to accept a threaded faster, so as to attached said first ends to said first flange, and wherein said first threaded portion is a threaded bore hole and said threaded fastener is a threaded bolt to be received within said threaded bore hole, wherein said first flange includes first, second and third slots to receive shaft portions of said threaded bolts, and wherein said second side of said first flange includes indentations formed alongside edges of said first, second and third slots to seat heads of said threaded bolts at different locations along said first, second and third slots.

6. The reel according to claim 2, further comprising: first, second and third partial or full funnel-shaped attachments mounted to or integrally formed with said first side of said second flange, each of said first, second and third partial or full funnel-shaped attachments being located adjacent to said first, second and third through holes, respectively, to guide said second ends of said first, second and third elongated members toward and into said first, second and third through holes, respectively.

7. The reel according to claim 1, wherein at least one of said first, second and third elongated members is spring biased to be offset radially outward away from said guidepost, and can be moved radially inward toward said guidepost against the spring bias.

8. The reel according to claim 1, wherein said first, second and third elongated members are spring biased to be offset radially outward away from said guidepost, and can be moved radially inward toward said guidepost against the spring bias, and wherein said first, second and third through holes in said second flange are shaped as arcuate slots, and wherein first, second and third springs are anchored to said first flange and to each of said first, second and third elongated members, respectively, and tend to bias each of said first, second and third elongated members to an end of its respective arcuate slot within said second flange, which is more radially spaced from said guidepost than an opposite end of its respective arcuate slot.

9. The reel according to claim 1, wherein said guidepost is formed as a generally cylindrical shaft, and wherein said first part of said lock set is formed as a plurality of locking holes, each locking hole of said plurality of locking holes being spaced apart from other locking holes of said plurality of locking holes in a direction from said second end of said guidepost to said first end of said guidepost; and wherein said second part of said lock set is formed as a collar attached to said second flange, said collar having an inner opening which is larger than a diameter of said generally cylindrical shaft, so that said collar may slide over a section of said shaft, said collar including a spring-loaded plunger captured therein, said spring-loaded plunger having a pin biased to extend away from said collar toward said guidepost and to engage within a user selected locking hole of said plurality of locking holes, and wherein said spring-loaded plunger includes a handle attached to said pin to manually pull said pin away from said guidepost and disengage said pin from said locking hole.

10. The reel according to claim 1, further comprising; a coil of cable encircling said hub formed by said first, second and third elongated members, and residing between said first and second flanges.

11. The reel according to claim 1, wherein said guidepost includes a first end opening formed into said first end of said guidepost, which extends into said guidepost in the direction of said second end of said guidepost, and a second end opening formed into said second end of said guidepost, which extends into said guidepost in the direction of said first end of said guidepost, and further comprising: a first polymer bushing received within said first end opening; anda second polymer bushing received within said second end opening, and wherein said first polymer bushing includes a first lip extending outside of said first end opening of said guidepost, and wherein said second polymer bushing includes a second lip extending outside of said second end opening of said guidepost.

12. The reel according to claim 11, further comprising: a first o-ring seated into a first groove formed within said first lip; anda second o-ring seated into a second groove formed within said second lip, wherein said first o-ring generates a frictional force tending to resist rotation of said first lip around a first spindle inserted into said first bushing, and said second o-ring generates a frictional force tending to resist rotation of said second lip around a second spindle inserted into said second bushing.

13. The reel according to claim 1, further comprising: a parking brake having a first feature attached to one of said first and second ends of said guidepost for selective locking with a second feature attached to a reel support, so that rotation of said reel relative to the reel support is blocked when said first feature of said parking brake is lock to the second feature.

14. The reel according to claim 13, wherein said first feature is a parking brake through hole formed within a parking brake plate attached to said second end of said guidepost.

15. A reel for storing a coil of communication cable comprising: a first flange having a first side and a second side;a plurality of arcuate first slots formed within said first side of said first flange, each slot of said plurality of arcuate first slots having a first end closer to a center of said first flange than a second end;a second flange having a first side and a second side, where said first side of said second flange faces to said first side of said first flange;a plurality of arcuate second slots formed within said first side of said second flange, each slot of said plurality of arcuate second slots having a first end closer to a center of said second flange than a second end;a plurality of elongated member, each elongated member having a first end within or passing through one of said plurality of arcuate first slots, and an opposite, second end within or passing through one of said plurality of arcuate second slots, wherein said plurality of elongated members have surfaces serving as a hub for a coil of cable placed between said first and second flanges;at least one biasing member causing said plurality of elongated members to assume positions within said pluralities of arcuate first and second slots so as to bear against said second ends of said arcuate first and second slots; anda guidepost attached to said first flange and extending away from said first side of said first flange and being attached to said second flange to hold said second flange at a set distance from said first flange.

16. The reel according to claim 15, wherein said guidepost is a central shaft attached to a center of said first flange and passing through a central shaft opening within said second flange, and further comprising: a lock set attached to said central shaft and to said second flange and being manually actuated to engage said second flange to said central shaft and disengage said second flange from central shaft, so that said second flange may be slid along said central shaft to a desired position and then fixed to said central shaft by actuating said lock set to hold said second flange at a fixed distance from said first flange.

17. The reel according to claim 16, wherein said lock set includes a second part in the form of a spring-loaded collar attached to said second flange, which is biased to frictionally engage with a first part in the form of ribbed rings formed along said central shaft, said spring-loaded collar being releasable by finger pressure to allow said spring-loaded collar to slide along said central shaft until the finger pressure is removed.

18. The reel according to claim 16, wherein said second ends of said plurality of elongated members extend through said plurality of arcuate second slots and further away from said second side of said second flange, as said second flange is moved closed to said first flange.

19. The reel according to claim 15, wherein said plurality of arcuate first slots pass entirely through said first flange, and wherein said first ends of said plurality of elongated members pass entirely through said plurality of arcuate first slots to reside beyond said second side of said first flange.

20. The reel according to claim 15, wherein said plurality of elongated members is formed by six cylindrical rods, and wherein said at least one biasing member includes: a plurality of actuating arms, each arm with a first end pivotally attached to said first flange and a second end attached to one of said plurality of elongated members; anda plurality of springs, each spring having a first end attached to said first flange and a second end attached to one of said plurality of actuating arms, wherein said plurality of springs bias said plurality of actuating arms to cause said plurality of elongated members to assume positions in abutment with said second ends of said pluralities of arcuate first and second slots.