CABLE REEL WITH AXIALLY ADJUSTABLE COUPLING MECHANISM

FIELD OF THE INVENTION

The present invention relates to a cable reel and also to a method for installing cable on the cable reel.

BACKGROUND OF THE INVENTION

Cable installers are commonly required to carry cable to installation locations. The installers usually use some type of shoulder bag or other types of packing solutions with an opening for paying out the cable. These cables are often wound on a reel to form a cable coil and packaged in a box or bag for payout during installations. When the cable coil shifts before or during installation on the cable reel, the dimensions of the cable coil can no longer fit on the cable reel.

SUMMARY OF THE INVENTION

Accordingly, the present invention may provide a cable reel that has first and second opposing flanges. The first flange has a first hub portion, and the second flange has a second hub portion. The first and second hub portions are axially aligned and configured to mate with one another to support cable, such as a cable coil. The first hub portion includes an elongated wall that extends from the first flange. The elongated wall is sized to support the cable. The elongated wall defines an inner area that is configured to accept the second hub portion. The elongated wall includes a plurality of flexible segments. The second hub portion includes a truncated wall that is receivable in the inner area of the first hub portion. The truncated wall includes a tapered outer surface for engaging and expanding the plurality of flexible segments.

The present disclosure may also provide an axially adjustable coupling mechanism for coupling the first hub portion to the second hub portion to accommodate cable coils of different sizes. In some embodiments, the axially adjustable coupling mechanism includes a threaded connection that is continuously adjustable in the axial direction. In some embodiments, the axially adjustable coupling mechanism includes a snap connection that provides discrete stable positions in the axial direction. In some embodiments, the axially adjustable coupling mechanism includes a ratcheting pawl or other mechanism to limit or prevent the loosening of the axially adjustable coupling mechanism during use.

The present disclosure may also provide a cable reel that includes at least one support frame that has an outwardly extending braking gear member. The outwardly extending gear member is located off-center on the frame. A first flange has a central opening and a first hub portion that surrounds the central opening. The central opening has an internal braking gear member that engages the outwardly extending gear member of the frame, thereby rotatably coupling the at least one support frame and the first flange. A second flange opposes the first flange and has a second hub portion. The first and second hub portions are configured to mate with one another to support cable. The engagement of the gear members provides a friction for cable payoff.

The present disclosure may additionally provide a cable reel that has at least one support frame having an outwardly extending braking gear member and a first flange having a central opening with an internal braking gear member of the frame, thereby rotatably coupling the at least one support frame and the first flange. A hub is provided between the first flange and a second flange that opposed the first flange. The hub is configured to support a cable, wherein the engagement of the gear members provides friction for cable payoff from the hub.

The present disclosure may further provide a cable reel that comprises first and second support frames that each have an outwardly extending braking gear member and first and second flanges that each have a central opening with an internal braking gear member engaging the outwardly extending gear members of the first and second support frames, respectively, thereby rotatably coupling the first support frame and the first flange and rotatably coupling the second support frame and the second flange. A hub is between the first flange and a second flange and is configured to support cable. The engagement of the gear members provides friction for cable payoff from the hub.

The present disclosure may further provide a method of installing the cable, such as a cable coil, on a cable reel that includes the steps of providing a cable reel that includes first and second opposing flanges, the first flange having a first hub portion and the second flange having a second hub portion, the first hub portion being longer than the second hub portion, and the first hub portion having a plurality of flexible segments; placing a cable coil over the first hub portion and on the first flange so that the first hub portion extends through the cable coil; and inserting the second hub portion inside of the first hub portion, thereby expanding the flexible segments so that the flexible segments engage the cable coil.

The present disclosure may yet further provide a method of installing cable on a cable reel comprising the steps of providing a cable reel that includes first and second opposing flanges where the first flange has a first hub portion and the second flange has a second hub portion and the first hub portion has one or more flexible segments; placing a cable coil over the first hub portion and on the first flange so that the first hub portion substantially extends through an inner diameter of the cable coil; and expanding the one or more flexible segments by inserting the second hub portion inside of the first hub portion so that the one or more flexible segments engage the cable coil.

The present disclosure may also further provide a method of installing cable on a cable reel, comprising the steps of providing a cable reel that includes first and second frames that rotatably support first and second opposing flanges, respectively, where the first flange has a first hub portion and the second flange has a second hub portion and the first hub portion ha an elongated wall that defines a receiving area for a truncated wall of the second hub portion; placing a cable coil over the first hub portion and on the first flange so that the first hub portion substantially extends through an inner diameter of the cable coil; and inserting the truncated wall of the second hub portion inside of the receiving area of the first hub portion, thereby retaining the cable coil between the first and second frames such that the cable coil rotates with respect to the first and second frames, thereby allowing payout of the cable of the cable coil.

The present disclosure relates to a method of installing a coil of cable in a bag, that comprises the steps of: placing a coil of cable on a first hub of a first flange of a cable reel; placing a second flange of the cable reel, that is separable from the first flange, opposite from the first flange to hold the coil of cable on the first hub of the first flange; positioning the first flange on or next to a first support frame received in the bag; and placing the second flange on or next to a second support frame received in the bag. The second support frame is positioned in the bag such that the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame.

In other examples, the method further comprises the step of disengaging the first flange from the second flange; further comprises the step of disengaging the first flange from the second flange after opening the bag; and/or further comprises the steps of rotatably coupling the first flange and the first frame and rotatably coupling the second flange and the second frame.

The present disclosure relates to a method of installing a coil of cable in a bag, that comprises the steps of: placing a coil of cable on a first hub of a first flange of the cable reel; placing a second flange of the cable reel opposite from the first flange to hold the coil of cable on the first hub of the first flange; positioning the first flange on or next to a first support frame located in the bag; and placing the second flange on or next to a second support frame located in the bag, wherein the second support frame is positionable in the bag such that the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame. The step of placing the coil of cable on the first hub of the first flange occurs before the step of positioning the first flange on the first support frame.

In certain examples, the step of placing the second flange of the cable reel opposite from the first flange to hold the coil of cable on the first hub of the first flange includes engaging a second hub of the second flange with the first hub; and/or the method further comprises the step of disengaging the second hub from the first hub after opening the bag.

The present disclosure relates to a method of installing a coil of cable in a bag, the bag having a cover for opening the bag, a base opposite the cover, and sides extending between the cover and the base, the method comprising the steps of: placing a coil of cable on a first hub of a first flange of a cable reel; placing a second flange of the cable reel, that is separable from the first flange, opposite from the first flange to hold the coil of cable on the first hub of the first flange; positioning the first flange on or next to a first support frame received in the bag, the first support frame being on an inner surface of the base of the bag; and placing the second flange on or next to a second support frame received in the bag, the second support frame being on an inner surface of the cover of the bag. When the cover of the bag is closed, the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame inside the bag.

In some examples, the method further comprises the step of engaging the first and second flanges after placing the second flange opposite from the first flange, thereby holding the coil of cable between the first and second flanges; the step of engaging the first and second flanges includes engaging a second hub of the second flange with the first hub of the first flange; the method further comprises the step of disengaging the first flange from the second flange; the method further comprises the step of opening the bag by opening the cover and the step of disengaging the first flange from the second flange occurs after opening the bag; and/or the method further comprises the steps of rotatably coupling the first flange and the first frame and rotatably coupling the second flange and the second frame.

In other examples, the coil of cable is prepacked with a plastic wrap prior to the step of placing the coil of cable on the first hub of the first flange; and/or the method further comprises the step of dispensing the cable through a payout slot in the bag.

The present disclosure may yet further relate to a method of installing a cable reel in a bag, the cable reel comprising a first flange with a first hub portion and a second flange with a second hub portion, the method can comprise the steps of: placing the first flange on a first support frame secured to a base of the bag, wherein either the first hub portion or the second hub portion includes an elongated wall and the other of the first hub portion and the second hub portion includes a truncated wall; and releasably coupling the elongated wall and the truncated wall together to form a hub member configured to support a coil of cable.

In certain examples, the elongated wall and the truncated wall are releasably coupled by a friction fit therebetween; the method further comprises the step of placing the coil of cable on the elongated wall prior to the step of releasably coupling the elongated wall and the truncated wall together; the method further comprises the step of dispensing cable of the cable coil through a payout slot in the bag after the step of releasably coupling the elongated wall and the truncated wall together; the method further comprises the step of decoupling the elongated wall and the truncated wall from one another for replacement of the coil of cable with another coil of cable; at least a portion of the truncated wall is received in a receiving area of the elongated wall when releasably coupling the elongated wall and the truncated wall together; the elongated wall is an annular wall and the truncated wall is an annular wall; the first flange and the elongated wall are integral, and the second flange and the truncated wall are integral; the first hub portion includes a first engagement member configured to engage a second engagement member of the second hub portion; and/or the method further comprises the step of locking the first flange to the second flange.

The present disclosure may also relate to a method of installing a cable reel in a bag, that can comprise the steps of releasably coupling a hub portion of a first flange of the cable reel with a second flange of the cable reel, the hub portion being configured to support a coil of cable; placing a coil of cable on the hub portion; and placing the first flange on a first support frame secured to the bag for dispensing the cable from the bag.

In some examples, the hub portion comprises a wall; the step of releasably coupling the hub portion and the second flange includes inserting another hub portion of the second flange into a receiving area of the hub portion of the first flange; the step of releasably coupling the hub portion includes coupling the hub portion and another hub portion of the second flange by a friction fit; the hub portion includes a first engagement member configured to engage a second engagement member of another hub portion of the second flange; the first flange and the hub portion form one-piece; and/or the step of placing the coil of cable on the hub portion occurs before releasably coupling the hub portion and the second flange.

The present disclosure may further relate to a method of installing a coil of cable in a bag, that can comprise the steps of: placing a pre-wound, reel-less coil of cable on a hub portion of a first flange; after placing the coil of cable on the hub portion of the first flange, releasably coupling the hub portion to a second flange, to form a hub that holds the coil of cable between the first and second flanges; and placing the first flange and the second flange with the coil of cable therebetween into the bag.

In certain examples, the method further comprises the step of positioning the first flange on or next to a first support frame received in the bag, the first support frame being on an inner surface a base of the bag; and/or the method further comprises the step of positioning the second flange on or next to a second support frame received in the bag, the second support frame being on an inner surface of a cover of the bag, wherein, when the cover of the bag is closed, the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame inside the bag.

In other examples of the method, the reel-less coil of cable is pre-wound prior to the step of placing the coil of cable on the hub portion of the first flange; the method further comprises the step of dispensing cable of the coil of cable from the bag; the method further comprises the step of decoupling the hub portion and the second flange; the method further comprises the step of placing another pre-wound reel-less coil of cable on the hub portion after the step of decoupling the hub portion and the second flange; the hub portion comprises an elongated wall; the step of releasably coupling the hub portion and the second flange comprises releasably coupling the hub portion with another hub portion of the second flange; and/or the hub portion and the another hub portion form a friction fit.

The present disclosure may also provide a method of installing a coil of cable in a bag, that can comprise the steps of providing a user with a cable reel, the cable reel comprising a first flange and a second flange, the first flange having a hub member configured to releasably couple to the second flange; instructing the user to place the coil of cable on the hub member and then releasably couple the hub member with the second flange with the coil of cable between the first and second flanges; and instructing the user to place the cable reel with the coil of cable into the bag for dispensing of the cable. In the example, the method further comprises the step of providing the user the coil of cable that is pre-wound and reel-less.

The present disclosure further provides a kit (e.g., a cable reel kit) of separate components for assembly of a cable reel apparatus that comprises a bag that has a base with a first inside surface and a cover with a second inside surface, wherein the bag is sized to hold a coil of cable; a first frame that has a geometry configured for placement on one of the first inside surface or the second inside surface of the bag; and a second frame that has a geometry configured for placement on another one of the first inside surface or the second inside surface of the bag. A first flange that has an inner surface, an outer surface, a first hub portion, and a central opening for engaging the first frame such that, when engaged, the outer surface of the first flange faces the first frame. A second flange that has an inner surface, an outer surface, a second hub portion, and a central opening for engaging the second frame such that, when engaged, the outer surface of the second flange faces the second frame. Either the first hub portion or the second hub portion includes an elongated wall and the other of the first hub portion and the second hub portion includes a truncated wall, the truncated wall and the elongated wall being configured to releasably couple to form a hub member configured to support the coil of cable.

In certain examples, one or both of the elongated wall and the truncated wall is an annular wall that extends transversely to a plane of the inner surface of the respective first or second flange; the truncated wall is sized to fit within a receiving area of the elongated wall; more than half of the length of the truncated wall is sized to fit within the receiving area of the elongated wall; the first and second hub portions are configured to interlock with one another; the geometry of the first and second frames is substantially square; the first flange and the first hub portion are one-piece and the second flange and the second hub portion are one-piece; and/or the bag includes a payout opening sized for dispensing of the cable of the coil of cable.

The present disclosure additionally provides a kit of separate components for assembly of a cable reel apparatus that comprises a pre-wound coil of cable, the coil of cable has an inner diameter; a bag sized to hold the coil of cable, the bag has a base and a cover; a first frame that has a geometry configured to fit inside of the base of the bag; and a second frame that has a geometry configured to fit on an inside surface of the cover of the bag. A first flange that has an inner surface and an outer surface and is configured for engaging the first frame such that the outer surface of the first flange faces the first frame, and the first flange has a first hub portion on the inner surface of the first flange. A second flange that has an inner surface and an outer surface and is configured for engaging the second frame such that the outer surface of the second flange faces the second frame, and the second flange has a second hub portion on the inner surface of the second flange. The first and second hub portions are sized to fit within the inner diameter of the coil of cable and are configured to releasably couple with one another to form a hub member for supporting the coil of cable between the first and second flanges.

In some examples, the coil of cable is prepackaged without a reel; the coil of cable is prepackaged with plastic wrap; the first hub portion has an inner friction surface and the second hub portion has an outer friction surface such that when the first and second hub portions are engaged, a friction fit is formed therebetween; one of the first and second hub portions is an elongated annular wall and the other of the first and second hub portions is a truncated annular wall, and the elongated and truncated walls extend substantially perpendicularly to a plane of the inner surface of the respective first or second flange; the geometry of the first and second frames is substantially square; the first flange and the first hub portion are one-piece and the second flange and the second hub portion are one-piece; and/or the bag includes a payout opening sized for dispensing of the cable of the coil of cable.

The present disclosure also provides a kit of separate components for assembly of cable reel apparatus that comprises a reel-less pre-wound coil of cable, the coil of cable has an inner diameter; a bag sized to hold the coil of cable, the bag has a base and a cover; a first frame has a geometry configured to fit inside of the base of the bag; and a second frame has a geometry configured to fit on an inside surface of the cover of the bag. A first flange has an inner surface and an outer surface and is configured for engaging the first frame such that the outer surface of the first flange faces the first frame. A second flange that has an inner surface and an outer surface and is configured for engaging the second frame such that the outer surface of the second flange faces the second frame. At least one of the first and second flanges has a wall sized to fit within the inner diameter of the coil of cable, and the wall is configured to releasably couple with the other of the first and second flanges.

In certain examples, the wall is an elongated annular wall; the elongated annular wall is configured to releasably couple with an inner surface of the other of the first and second flanges; the one of the first and second flanges and the elongated annular wall are one-piece; and/or the coil of cable is prepackaged with plastic wrap.

The present disclosure may further provide a cable payout apparatus that comprises a bag that has a base, a cover, and a payout opening for dispensing cable, a first frame inside the bag, and a second frame inside the bag. A first flange is configured to be rotatably coupled to the first frame and has an inner side, an outer side, and a central opening, the outer side of the first flange faces the first frame. A second flange is configured to be coupled to the second frame and has an inner side, an outer side, and a central opening, the outer side of the second flange faces the second frame. An elongated wall extends from the inner side of the first flange and releasably couples to the second flange. The elongated wall for supporting a coil of cable between the first and second flanges. The first frame is positioned in the base of the bag and the second frame is positioned at the cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, the second frame releasably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, the second frame decouples from the second flange.

In certain examples, the first flange and the elongated wall form one-piece; the hub portion and the second flange are releasably coupled by a friction fit; the second flange includes a truncated wall extending transversely from the inner side of the second flange, and the truncated wall is configured to releasably couple to the elongated wall; at least a portion of the truncated wall is received in a receiving area of the elongated wall when releasably coupling the elongated wall and the truncated wall together; the truncated wall extends about the central opening; the coil of cable defines an inner diameter, wherein the elongated wall and the truncated wall are configured to extend into the inner diameter to support the coil of cable; and/or each of the elongated and truncated wall is annular.

In other examples, the coil of cable has an inner diameter, and the elongated wall is sized to be received in the inner diameter when supporting the coil of cable, the coil of cable is prepackaged without a reel; the bag is configured such that the second flange is removable from the elongated wall allowing the coil of cable to be loaded onto the elongated wall; and/or the second flange is released from the elongated wall.

The present disclosure also further provides a cable payout apparatus that comprises a bag that has a base, a cover, and a payout opening for dispensing cable, a first frame inside the bag, and a second frame inside the bag. A first flange is positioned on the first frame, the first flange has an inner side and an outer side, the outer side of the first flange faces the first frame, and a first hub portion on the inner side of the first flange. A second flange is positioned on the second frame, the second flange has an inner side and an outer side, the outer side of the second flange faces the second frame, and a second hub portion on the inner side of the second flange. The first hub portion and the second hub portion are configured to releasably couple with one another to form a hub member for supporting a coil of cable between the first and second flanges. The first frame is positioned in the base of the bag and the second frame is positioned at the cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, the second frame releasably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, the second frame decouples from the second flange.

In some examples, the coil of cable is prepackaged without a reel; the coil of cable is prepackaged with plastic wrap; the first hub portion has an inner friction surface and the second hub portion has an outer friction surface such that when the first and second hub portions are coupled, a friction fit is formed therebetween; one of the first and second hub portions is an elongated wall; one of the first and second hub portions is an elongated annular wall and the other of the first and second hub portions is a truncated annular wall, and the elongated and truncated annular walls extend transversely from the inner side of the respective first or second flanges; at least portion of the truncated annular wall is sized to be received in a receiving area of the elongated annular wall; and/or the first flange and the first hub portion form one-piece and the second flange and the second hub portion form one-piece.

The present disclosure may also provide a cable payout apparatus that comprises a bag that has a base, a cover, and a payout opening for dispensing cable, a first frame inside the bag, and a second frame inside the bag. A first flange is configured to be rotatably coupled to the first frame, the first flange has an inner side, an outer side, and a central opening, and the outer side of the first flange facing the first frame. A second flange is configured to be rotatably coupled to the second frame, the second flange has an inner side, an outer side, and a central opening, and the outer side of the second flange facing the second frame. An elongated annular wall extends from the inner side of the first flange and extends in a direction transverse with respect to the first flange. A truncated annular wall extends from the inner side of the second flange and extends in a direction transverse with respect to the second flange and releasably couples to the elongated annular wall to form a hub member that supports a pre-wound reel-less coil of cable between the first and second flanges. The first frame is positioned in the base of the bag and the second frame is positioned at the cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, the second frame rotatably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, the second frame decouples from the second flange.

An aspect of the present disclosure is a cable reel apparatus that comprises a cable reel for holding a coil of cable, and the cable reel includes a central longitudinal axis, a first flange configured to be rotatably coupled to a first frame, the first flange having opposite inner and outer sides, and the inner side of the first flange having an elongated wall extending transversely therefrom along the central longitudinal axis of the cable reel, and a second flange separate from the first flange that is configured to be rotatably coupled to a second frame, the second flange has opposite inner and outer sides, and the inner side of the second flange has a truncated wall extending transversely therefrom along the central longitudinal axis of the cable reel. The elongated wall and the truncated wall are configured to be releasably coupled to one another for supporting a coil of cable between the first and second flanges and are configured to be decoupled from one another when replacing the coil of cable once dispensed from the cable reel apparatus.

In certain examples, the coil of cable has an inner diameter, and the elongated and truncated walls are sized to be received in the inner diameter when supporting the coil of cable, the coil of cable is prepacked without a cable reel, the first frame and the second frame are disposed on inner surfaces of a bag that has a payout opening for dispensing cable of the coil of cable; the bag is configured such that the second flange is removable from the elongated wall of the first flange allowing the coil of cable to be loaded on and unloaded from the elongated wall; the first fame is positioned in a base of the bag and the second frame is positioned at a cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, the second frame releasably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, the second frame decouples from the second flange; the first flange and the elongated wall form one-piece and the second flange and the truncated wall form one-piece; the elongated wall and the truncated wall are releasably coupled by a friction fit; at least a portion of the truncated wall is received inside a receiving area of the elongated wall when releasably coupling the elongated wall and the truncated wall together; and/or the elongated wall and the truncated wall each extend about a central opening in the first and second flanges, respectively.

Another aspect of the present disclosure is a cable reel apparatus that comprises a bag that has a base, a cover, and a payout opening for dispensing cable; a first frame configured to be received inside the bag; and a second frame configured to be received inside the bag. A first flange is configured to be positioned on the first frame, and the first flange has an inner side and an outer side, the outer side of the first flange facing the first frame, and a first hub portion on the inner side of the first flange. A second flange that is separate from the first flange is configured to be positioned on the second frame, and the second flange has an inner side and an outer side, the outer side of the second flange facing the second frame, and a second hub portion on the inner side of the second flange. The first hub portion and the second hub portion are configured to be releasably coupled to one another for supporting a coil of cable between the first and second flanges and are configured to be decoupled from one another when replacing the coil of cable once dispensed from the cable reel apparatus.

In some examples, the coil of cable is prepackaged without a reel; the coil of cable is prepackaged with plastic wrap; the first hub portion has an inner friction surface and the second hub portion has an outer friction surface such that when the first and second hub portions are releasably coupled, a friction fit is formed therebetween; one of the first and second hub portions is an elongated wall; one of the first and second hub portions is an elongated annular wall and the other of the first and second hub portions is a truncated annular wall, and the elongated and truncated annular walls extend transversely from the inner side of the respective first or second flanges; and/or at least a portion of the truncated annular wall is sized to be received in a receiving area of the elongated annular wall.

A further aspect of the present disclosure is a cable reel apparatus that comprises a first flange configured to be rotatably coupled to a first frame, the first flange having an inner side, an outer side, and a central opening, the outer side of the first flange facing the first frame, and a first hub portion extends from the inner side of the first flange. A second flange is separate from the first flange that is con-figured to be coupled to a second frame. The second flange has an inner side, an outer side, and a central opening, and he outer side of the second flange facing the second frame, and a second hub portion extends from the inner side of the second flange. And means for releasably coupling the first hub portion and the second hub portion to form a hub member that supports a pre-wound reel-less coil of cable between the first and second flanges and decoupling the first hub portion and the second hub portion from one another when replacing the coil of cable once dispensed from the cable reel apparatus.

In some examples, the first frame is positioned in a base of a bag that has a payout opening for dispensing cable the second frame is positioned at a cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, and the second frame rotatably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, the second frame decouples from the second flange; and/or at least one of the first and second hub portions is an elongated annular wall.

Yet another aspect of the present disclosure is a cable reel apparatus that comprises a bag, a first frame that is configured to be received inside the bag; a first flange that is configured to be removably engaged with the first frame; a second frame that is configured to be received inside the bag; a second flange that is configured to be removably engaged with the second frame; and a hub member that is configured to releasably couple said first flange with the second flange, and the hub member configured to support a coil of cable.

In some examples, the first flange has an inner surface, and the hub member extends from the inner surface of the first flange and is configured to be releasably coupled with said second flange; and/or the hub member comprises a first hub portion that extends from the inner surface of the fir flange and a second hub portion extends from an inner surface of the second flange, and the first hub portion is configured to be releasably coupled with the second hub portion; the bag has a first side and a second side, and the first frame is configured to be positioned at the first side of the bag, and the second frame is configured to be positioned at the second side of the bag; the first side comprises a cover of the bag and the second side comprises a base of the bag; and/or the second frame is configured to releasably couple with said second flange when the cover is closed, and said second frame is configured to decouple from said second flange when the cover is opened.

An aspect of the present disclosure is a system for using a cable reel apparatus that comprises providing components of a separable cable reel for assembly of a cable reel apparatus. The components of the separable cable reel include a first frame, a second frame, and the second frame is separate from the first frame. A first flange is configured to engage the first frame. The first flange has an inner side and an outer side, and the outer side of the first flange faces the first frame when the first flange is engaged therewith. A second flange is configured to engage the second frame. The second flange has an inner side and an outer side, and the outer side of the second flange faces the second frame when the second flange is engaged therewith. The system also comprises providing a pre-wound, reel-less coil of cable that is separate from the separable cable reel. The first and second flanges are configured to releasably couple with one another to support the pre-wound, reel-less coil of cable there between.

In certain examples, the system further comprises assembling the cable reel apparatus by releasably coupling the first and second flanges such that the respective inner sides thereof face one another to support the pre-wound, reel-less coil of cable therebetween along a central longitudinal axis of the separable cable reel; the system further comprises disassembling the cable reel apparatus by decoupling the first and second flanges; the system further comprises a bag having a base and a cover, wherein the bag is sized to hold the cable reel apparatus when assembled; the base of the bag has a cable payout opening sized for dispensing cable from the cable reel apparatus; the first frame has a geometry configured for placement on inside surface of the bag and wherein the second frame has a geometry configured for placement on another inside surface of the bag; the geometry of the first and second frames is substantially square; and/or each of the first and second flanges has a substantially disc shape.

In other examples, at least one of the first and second flanges includes a hub portion that is receivable in an inner diameter of the pre-wound, reel-less coil of cable; the hub portion extends transversely from the inner side of the at least one of the first and second flanges; the hub portion is an elongated wall; the first flange is one-piece and the second flange is one-piece; and/or the first and second flanges are configured to interlock with one another.

Another aspect of the present disclosure is a system for using a cable reel apparatus that comprises providing components of a separable cable reel for assembly of a cable reel apparatus. The components of the separable cable reel include a first frame and a second frame that is separate from the first frame. The components also include a first flange hat has an inner side and an outer side, and the first flange is configured for engaging the first frame such that the outer side of the first flange faces the first frame, and the first flange has a first hub portion on the inner side of the first flange, and a second flange that has an inner side and an outer side, and the second flange is configured for engaging the second frame such that the outer side of the second flange faces the second frame, and the second flange has a second hub portion on the inner side of the second flange. The system also comprises providing a pre-wound, reel-less coil of cable that is separate from the separable cable reel, and the first and second hub portions are sized to fit within the inner diameter of the coil of cable and are configured to releasably couple with one another to form a hub member for supporting the pre-wound, reel-less coil of cable between the first and second flanges.

In certain examples the coil of cable is prepackaged with plastic wrap; the first hub portion has an inner friction surface and the second hub portion has an outer friction surface such that when the first and second hub portions are engaged, a friction fit is formed therebetween; one of the first and second hub portions is an elongated annular wall and the other of the first and second hub portions is a truncated annular wall, and the elongated and truncated walls extend substantially perpendicularly to a plane of the inner side of the respective first or second flange; and/or the first flange and the first hub portion are one-piece and the second flange and the second hub portion are one-piece.

In other aspects, the system further comprises assembling the cable reel apparatus by releasably coupling the first and second hub portions to form a hub member to support the pre-wound, reel-less coil of cable therebetween along a central longitudinal axis of the separable cable reel; and/or disassembling the first and second hub portions.

Yet another aspect of the present disclosure is a system for using a cable reel apparatus that comprises providing components of a separable cable reel for assembly of a cable reel apparatus. The component of the separable cable reel Include a bag that has a base and a cover, wherein the bag is sized to hold the cable reel apparatus when assembled, a first frame sized to be disposed in the base of the bag, and a second frame sized to be disposed at the cover of the bag, and the second frame is separate from the first frame. A first flange is configured to engage the first frame, and the first flange has an inner side and an outer side, and the outer side of the first flange faces the first frame when the first flange is engaged therewith. A second flange is configured to engage the second frame, and the second flange has an inner side and an outer side, and the outer side of the second flange faces the second frame when the second flange is engaged therewith. A hub portion extends from the inner side of one of the first and second flanges. The system also comprises providing a pre-wound reel-less coil of cable that is separate from the separable cable reel, wherein the first and second flanges are configured to releasably couple with one another to support the pre-wound, reel-less coil of cable on the hub portion therebetween, and wherein the base of the bag includes a payout opening sized for dispensing cable of the pre-wound, reel-less coil of cable therebetween.

In certain examples, the system further comprises assembling he cable reel apparatus by releasably coupling the first and second flanges such that the respective inner sides thereof face one another to support the pre-wound, reel-less coil of cable therebetween along a central longitudinal axis of the separable cable reel; the system further comprises disassembling the cable reel apparatus by decoupling the first and second flanges; and/or the hub portion is an elongated wall.

An aspect of the present disclosure is a cable reel apparatus that comprises a cable reel for holding a coil of cable, and the cable reel includes a central longitudinal axis, a first flange that is configured to be rotatably coupled to a first frame, and the first flange has opposite inner and outer sides, and a second flange that is separate from the first flange and that is configured to be rotatably coupled to a second frame, and the second flange has opposite inner and outer sides. At least one of the first and second flanges includes a hub portion that extends transversely from the inner side thereof. The first and second flanges are configured to be releasably coupled to one another for supporting a coil of cable on the hub portion between the first and second flanges along the central longitudinal axis of the cable reel and are configured to be decoupled from one another when replacing the coil of cable once dispensed from the cable reel apparatus.

In certain examples, the coil of cable has an inner diameter, and the hub portion is sized to be received in the inner diameter when supporting the coil of cable; the coil of cable is prepackaged without a cable reel; the first frame and the second frame are disposed on inner surfaces of a bag that has a payout opening for dispensing cable of the coil of cable; the bag is configured such that the second flange is removable from the hub portion of the first flange allowing the coil of cable to be loaded on and unloaded from the hub portion; the first frame is positioned in a base of the bag and the second frame is positioned at a cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, the second frame releasably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, and the second frame decouples from the second flange; the hub portion is an annular elongated wall; and/or the first and second flanges are releasably coupled by a friction fit.

Another aspect of the present disclosure is a cable reel apparatus that comprises a bag that has a base, a cover, a payout opening for dispensing cable, a first frame, and a 55 second frame. A first flange is positioned on the first frame, and the first flange has an inner side and an outer side, and the outer side of the first flange faces the first frame. A second flange that is separate from the first flange is positioned on the second frame, and the second flange has an inner side and an outer side, and the outer side of the second flange facing the second frame. At least one of the first and second flanges includes a hub portion that extends transversely from the inner side thereof. The first flange and the second flange are configured to be releasably coupled to one 65 another for supporting a coil of cable on the hub portion between the first and second flanges and are configured to be decoupled from one another when replacing the coil of cable once dispensed from the cable reel apparatus.

In some examples, the coil of cable is prepackaged without a reel; the coil of cable is prepackaged with plastic wrap; the first and second flanges are releasably coupled by a friction fit; and/or the hub portion is an annular elongated wall.

A further aspect of this present disclosure is a cable reel apparatus that comprises a cable reel that includes a central 10 longitudinal axis, a first flange is configured to be rotatably coupled to a first frame, and the first flange has an inner side and an outer side, and the outer side of the first flange faces the first frame, and a second flange that is separate from the first flange that is configured to be coupled to a second frame, the second flange has an inner side and an outer side, and the outer side of the second flange faces the second frame. The cable reel apparatus also has means for releasably coupling to the first flange and the second flange to support a pre-wound, reel-less coil of cable between the first and second flanges along the central longitudinal axis of the cable reel and decoupling the first flange and the second flange from one another when replacing the coil of cable once dispensed from the cable reel apparatus.

In some examples, each of the first and second flanges includes a central opening for rotatably coupling to the first and second frames, respectively; the first flange is one-piece and the second flange is one-piece; the first frame is positioned in a base of a bag that has a payout opening for dispensing cable and the second frame is positioned at a cover of the bag, such that when the cover of the bag is closed with respect to the base of the bag, the second frame rotatably couples with the second flange and such that when the cover of the bag is opened with respect to the base of the bag, and the second frame decouples from the second flange; and/or the means for releasably coupling the first and second flanges includes a frictional fit; the coil of cable is prepack-aged; and/or the coil of cable is prepackaged with plastic wrap.

Yet another aspect of the present disclosure is a cable reel apparatus that comprises a bag that has a first side and a second side, a first flange that is configured to be positioned at the first side of the bag, and the first flange has an inner surface, and a second flange that is configured to be positioned at the second side of the bag. A hub member extends from the inner surface of the first flange and releasably couples with the second flange, and the hub member is configured to support a coil of cable.

In an example, the hub member comprises a first hub portion extending from the inner surface of the first flange and a second hub portion extends from the inner surface of the second flange, and the first hub portion is releasably coupled with the second hub portion.

An aspect of the present disclosure is a method of installing a coil of cable on a cable reel apparatus that comprises the steps of placing the coil of cable on a first flange of a separable cable reel of the cable reel apparatus; releasably coupling the first flange with a separate second flange of the separable cable reel after placing the coil of cable on the first flange; and placing the separable cable reel in a bag of the cable reel apparatus. The first flange includes a hub portion configured to be received in an inner diameter of the coil of cable, and the hub portion supports the coil of cable between the first and second flanges when the first and second flanges are releasably coupled. The coil of cable is a pre-wound, reel-less coil of cable.

In certain examples, the hub portion is a wall extending transversely from an inner side of the first flange, the wall is an elongated annular wall; the step of placing the separable cable reel in the bag occurs after the step of releasably coupling the first and second flanges; the method further comprises the step of dispensing the cable of the coil of cable through a payout slot in the bag after the step of releasably coupling the first and second flanges; the method further comprises the step of positioning the first flange on a first frame inside of the bag; the method further comprises the step of positioning the second flange on a second frame inside of the bag; and/or the first frame is secured to an inner surface of a base of the bag and the second frame is secured to an inner surface of a cover of the bag.

In other examples, the method further comprises the step of decoupling the first and second flanges from one another for replacement of the coil of cable with another coil of cable; the method further comprises the step of prepackaging the coil of cable; the step of prepackaging the coil of cable includes wrapping the coil of cable in plastic; the step of releasably coupling the first and second flanges includes coupling the first and second flanges by a friction fit; and/or the first flange and the hub portion form one-piece.

A further aspect of the present disclosure is a method of installing a coil of cable on a cable reel apparatus that comprises the steps of placing the coil of cable on a first hub portion of a first flange of a separable cable reel of the cable reel apparatus, the first hub portion extends from an inner side of the first flange and is configured to be received in an inner diameter of the coil of cable; releasably coupling the first hub portion of the first flange with a second hub portion of a second flange of the separable cable reel after placing the coil of cable on the first hub portion, thereby forming a hub member that supports the coil of cable between the first and second flanges, wherein the coil of cable is a pre-wound, reel-less coil of cable; and decoupling the first and second hub portions from one another for replacement of the coil of cable with another coil of cable.

In certain examples, the step of releasably coupling the first and second hub portions includes coupling the first and second hub portions by a friction fit; the method further comprises the steps of placing the separable cable reel in a bag of the cable reel apparatus and dispensing cable of the coil of cable through a payout slot in the bag after the step of releasably coupling the first and second flanges; the first flange includes a first engagement member configured to engage a second engagement member of the second flange; and/or the first flange and the first hub portion form one-piece and the second flange and the second hub portion form one-piece.

Yet another aspect of the present disclosure is a method of installing a coil of cable on a cable reel apparatus comprises the steps of placing the coil of cable on an elongated annular wall of a first flange of a separable cable reel of the cable reel apparatus, the elongated annular wall extends transversely from an inner side of the first flange and is configured to be received in an inner diameter of the coil of cable; after placing the coil of cable on the elongated annular wall, releasably coupling the elongated annular wall with a truncated annular wall of a second flange of the separable cable reel, thereby forming a hub member that supports the coil of cable between the first and second flanges, wherein the coil of cable is a pre-wound, reel-less coil of cable; placing the separable cable reel in a bag of the cable reel apparatus; and dispensing cable of the coil of cable out a payout opening in the bag.

In certain examples, the method further comprises the step of decoupling the elongated wall and the truncated wall from one another after the step of dispensing the cable; the method further comprises the step of placing another pre-wound, reel-less coil of cable on the elongate annular wall after the step of decoupling the elongated annular wall and the truncated annular wall from one another; at least a portion of the truncated annular wall is received in a receiving area of the elongated annular wall when releasably coupling the elongated annular wall and the truncated annular wall together; and/or the coil of cable is pre-wound prior to the step of placing the coil of cable on the elongated annular wall of the first flange.

An aspect of the present disclosure is a method of installing cable on a cable reel apparatus that comprises the steps of providing a pre-wound, reel-less coil of cable for installing on a separable cable reel. The separable cable reel comprises a central longitudinal axis, a first flange configured to be rotatably coupled to a first frame, and the first flange has opposite inner and outer sides, and a second flange that is separate from the first flange and is configured to be rotatably coupled to a second frame, and the second flange has opposite inner and outer sides. At least one of the first and second flanges includes a hub portion that extends transversely from the inner side thereof. The method also includes the step of instructing a user to releasably couple the first and second flanges to support the pre-wound, reel-less coil of cable on the hub portion between the first and second flanges along the central longitudinal axis of the separable cable reel.

In certain examples, the method further comprises the step of instructing the user to decouple the first and second flanges from one another when replacing the pre-wound, reel-less coil of cable once dispensed from the cable reel apparatus; the pre-wound, reel-less coil of cable has an inner diameter, and the hub portion is sized to be received in the inner diameter when releasably coupling the first and second flanges for supporting pre-wound, reel-less the coil of cable; the method further comprises the step of prepackaging the pre-wound, reel-less coil of cable; and/or the step of pre-packaging the pre-wound, reel-less coil of cable includes wrapping the pre-wound, reel-less coil of cable with plastic.

In other examples, the method further comprises the step of providing a bag sized to receive the separable cable reel and the pre-wound, reel-less coil of cable; the method further comprises the step of instructing the user to place the first frame on a first inner surface of the bag and place the second frame on a second inner surface of the bag; the bag has a base and a cover, and the base includes the first inner surface and the cover includes the second inner surface; the method further comprises the step of instructing the user to dispense cable of the pre-wound, reel-less coil of cable through a payout opening in the base of the bag; the method further comprises the step of instructing the user to close the cover on the base of the bag when releasably coupling the first and second flanges; the method further comprises the step of instructing the user to open the cover from the base of the bag when decoupling the first and second flanges; the hub portion is an annular elongated wall; and/or the first and second flanges are releasably coupled by a friction fit.

Another aspect of the present disclosure is a method of installing cable on a cable reel apparatus that comprises the steps of providing a bag having a base, a cover, a payout opening sized for dispensing cable, a first frame, and a second frame; providing a pre-wound, reel-less coil of cable for installing on a separable cable reel. The separable cable reel comprises a first flange for positioning on the first frame, he first flange has an inner side and an outer side, the outer side of the first flange for facing the first frame, a second flange that is separate from the first flange for positioning on the second frame, the second flange having an inner side and an outer side, the outer side of the second flange for facing the second frame, and at least one of the first and second flanges includes a hub portion that extends transversely from an inner side thereof. The method also comprises instructing a user to releasably couple the first and second flanges to support the pre-wound, reel-less coil of cable on the hub portion between the first and second flanges along a central longitudinal axis of the separable cable reel.

In some examples, the method further comprises the step of instructing the user to decouple the first and second flanges from one another when replacing the pre-wound, reel-less coil of cable once dispensed from the cable reel apparatus, the method further comprises the step of instructing the user to place the first frame on an inner surface of base of the bag and place the second frame on an inner surface of the cover of the bag; the method further comprises the step of prepackaging the pre-wound, reel-less coil of cable; the method further comprising the step of instructing the user to dispense cable of the pre-wound, reel-less coil of cable through a payout opening in the base of the bag; the method further comprises the step of instructing the user to close the cover on the base of the bag when releasably coupling the first and second flanges; and/or the method further comprises the step of instructing the user to open the cover from the base of the bag when decoupling the first and second flanges.

A further aspect of the present disclosure is a method of installing cable on a cable reel apparatus that comprises providing a bag having a base, a cover, a payout opening sized for dispensing cable, a first frame, and a second frame; and providing a pre-wound, reel-less coil of cable for installing on a separable cable reel. The separable cable reel comprises a first flange for positioning on the first frame, and the first flange has an inner side and an outer side, and the inner side of the first flange includes a first hub portion, and the outer side of the first flange facing the first frame; and a second flange that is separate from the first flange for positioning on the second frame, and the second flange has an inner side and an outer side, and the inner side of the second flange includes a second hub portion, and the outer side of the second flange for facing the second frame; and at least one of the first and second flanges includes a hub portion extending transversely from an inner side thereof. The method also comprises the step of instructing a user to releasably couple the first and second hub portions to form a hub member to support the pre-wound, reel-less coil of cable between the first and second flanges along a central longitudinal axis of the separable cable reel.

In an example, the first hub portion is an elongated annular wall, and the second hub portion is a truncated annular wall.

Yet another aspect of the present disclosure is a method of installing cable on a cable reel apparatus that comprises the steps of configuring the cable reel apparatus to have: a bag; a first frame configured to be received inside the bag; a first flange configured to be removably engaged with the first frame; a second frame configured to be received inside the bag; a second flange configured to be removably engaged with the second frame; and a hub member configured to releasably couple the first flange with the second flange, the hub member configured to support a coil of cable. The method also comprises providing a pre-wound, reel-less coil of cable.

In an example, the method further comprises instructing a user to install the coil of cable on the cable reel apparatus by decoupling the first flange from the second flange, placing the coil of cable on the hub member, and coupling the first flange to the second flange.

Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter. It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide an overview or framework to understand the nature and character of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: The accompanying drawings are incorporated in and constitute a part of this specification. It is to be understood that the drawings illustrate only some examples of the disclosure and other examples or combinations of various examples that are not specifically illustrated in the figures may still fall within the scope of this disclosure. Examples will now be described with additional detail through the use of the drawings, in which:

FIG. 1 is a perspective view of a cable reel in accordance with an exemplary embodiment of the present invention, shown with a supporting bag or box, according to at least one embodiment of the present disclosure;

FIG. 2 is a perspective view of a support frame of the cable reel illustrated in FIG. 1;

FIG. 3 is an elevational view of a flange of the cable reel illustrated in FIG. 1,

FIG. 4A is a perspective view of a first hub portion of the cable reel illustrated in FIG. 1;

FIG. 4B is a partial perspective view of the first hub portion illustrated in FIG. 4A, showing the hub in cross-section;

FIG. 5A is an elevational view of a second hub portion of the cable reel illustrated in FIG. 1;

FIG. 5B is a perspective view of the second hub portion of the cable reel illustrated in FIG. 5A;

FIG. 6 is an enlarged partial perspective view of the frame illustrated in FIG. 2, showing outer gears of the frame;

FIG. 7 is an enlarged partial side elevational view of the flange illustrated in FIG. 3, showing the inner gears of the flange;

FIG. 8 is an enlarged side elevational view of the frame and the flange of the cable reel illustrated in FIG. 1, showing the inner and outer gears engaged;

FIG. 9 is a side view of a cable reel with an axially adjustable coupling mechanism with a threaded connection, according to at least one embodiment of the present disclosure;

FIG. 10 is a side cross-sectional view of the cable reel with an axially adjustable coupling mechanism with a threaded connection of FIG. 9;

FIG. 11 is a side partial cross-sectional view of a cable reel with an axially adjustable coupling mechanism with a rotational ratcheting mechanism, according to at least one embodiment of the present disclosure;

FIG. 12 is a side partial cross-sectional view of a cable reel with an axially adjustable coupling mechanism with an axial ratcheting mechanism, according to at least one embodiment of the present disclosure;

FIG. 13 is a side cross-sectional view of a cable reel with an axially adjustable coupling mechanism with a threaded connection to a nut, according to at least one embodiment of the present disclosure;

FIG. 14 is a detail cross-sectional view of a cable reel with an axially adjustable coupling mechanism with a splined snap connection, according to at least one embodiment of the present disclosure;

FIG. 15 is a side cross-sectional view of a cable reel with an axially adjustable snap connection with a plurality of sets of recesses (e.g., engagement recesses), according to at least one embodiment of the present disclosure;

FIG. 16 is a side cross-sectional view of a cable reel with an axially adjustable snap connection with different length snap arms, according to at least one embodiment of the present disclosure; and

FIG. 17 is a side cross-sectional view of a cable reel with an axially adjustable snap connection with a plurality of sets of protrusions on snap arms, according to at least one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-3, 4A, 4B, 5A, 5B, and 6-8, the present invention relates to a cable reel 100 that may be carried in a conventional shoulder bag or satchel, a card-board or plastic box 101, and the like, with an opening 103 for easy payout of cable supported on the cable reel. The cable reel 100 according to an exemplary embodiment of the present invention is designed to provide easy installation of cable C, such as a cable coil, on the reel 100 and also prevents overpayout of the cable. Because the cable reel 100 is designed to be carried by an installer, it is preferable that the components of the cable reel 100 be formed of lighter weight materials, such as plastic. Some exemplary plastic materials include polyethylene, polypropylene, ABS, or other polymer products.

As seen in FIG. 1, the cable reel 100 generally includes opposing support frames 102 and 104 that rotatably support first and second flanges 106 and 108 with a hub member 110 therebetween on which the cable is held. A braking mechanism 112 is preferably provided on the reel 100 between the support frames 102 and 104 of the flanges 106 and 108 to limit overpayout of the cable. The cable reel 100 may be inserted into and supported by the payout bag or box wherein the support frames 102 and 104 are attached, preferably removably attached, to the cover and base, respectively, of the bag.

As seen in FIGS. 2 and 6, each support frame 102 and 104 includes an outer frame portion 120 with one or more cross members 122 and a middle flange support 124. The outer frame portion 120 may have a substantially square geometry. The middle flange support 124 includes an annular extension 126 (FIG. 6) that supports a first part of the braking mechanism 112. The first part of the braking mechanism may be an outwardly extending gear member 128 that includes a plurality of annularly arranged teeth 130 extending radially outwardly from the annular extension 126.

The middle flange support 124 and gear member 128 are offset or off-center on the frame such that the distance d1 (FIG. 2) to one end 132 of the frame is longer than the distance d2 (FIG. 2) to the opposite end 135 of the frame. This offset provides a gap 134, as seen in FIG. 8, in the braking mechanism 112. Indicia 136, such as a company name, may be provided on the end 132 of the frame to indicate the longer side, which is distance d1 of the frame to facilitate the orientation of the cable reel 100 in the bag or box.

Each flange 106 and 108 is preferably sized to fit within the outer frame portion 120 of its respective support frame 102 and 104 and is sized to accommodate the cable such as a cable coil. The cable coil may, for example, have an outer diameter of 345 mm and an inner diameter of 200 mm and a height of 135 mm. The flanges 106 and 108 are preferably disc-shaped. Each flange has inner and outer surfaces 140 and 142 and a central arbor opening 144. The inner surface 140 of each flange abuts the hub member 110 and the outer surface 142 abuts a respective support frame 102 and 104.

The central arbor opening 144 corresponds to the middle flange support 124 of each respective support frame. The central arbor opening 144 supports the second part of the braking mechanism 112 as seen in FIGS. 3 and 7. The second part of the braking mechanism 112 may be an internal gear member 146 that includes a plurality of annular arranged teeth 148 extending radially inwardly.

The hub member 110 is located between the flanges 106 and 108 and supports the cable coil. The hub member 110 includes a first hub portion 150 (FIGS. 4A and 4B) and a second hub portion 152 (FIGS. SA and 5B) that are axially aligned and configured to mate with one another. The hub portions 150 and 152 may be formed separately from the respective flanges 106 and 108 and attached thereto or the hub portions 150 and 152 may be formed as one-piece with the respective flanges 106 and 108.

As seen in FIGS. 4A and 4B, the first hub portion 150 is preferably the base of the cable reel and provides the main support for the cable. As such, the first hub portion 150 is larger than the second hub portion 152. The first hub portion 150 includes an elongated wall 154 that extends from the inner surface 140 of the first flange 106 and defines an inner area 156 that receives the second hub portion 152. The elongated wall 154 has a tapered outer surface 158 that tapers inwardly from the flange inner surface 140 to the free end 160 of the wall 154. Slots 162 in the elongated wall 154 create flexible segments 164, which engage both the second hub portion 152 and the cable coil to retain the same. A groove 166 (FIG. 4B) may be located at the base of the elongated wall 154 to provide additional flexibility to the segments 164. Any other mechanism may be provided to add flexibility to the segments 164. For example, the segments 164 can be made thinner.

Secondary engagement members 170 may be provided as a back-up to retain the hub portions 150 and 152 together. The secondary engagement members 170 may be, for example, one or more snap arms 172 provided in the inner area 156 that extend from the flange inner surface 140. The one or more snap arms 172 preferably extend beyond the elongated wall 154 of the first hub portion 150, as seen in FIG. 4A, in order to engage the second flange 108. The ends of the snap arms 172 preferably include snap tabs 174 that engage corresponding slots 176 (FIG. 5B) in the second flange 108. Although a snapping engagement is preferred to secure the hub portions 150 and 152 together, any known interlocking mechanism may be used.

As seen in FIGS. 5A and 5B, the second hub portion 152 includes a truncated wall 180 that extends from the inner surface 140 of the second flange 108. The truncated wall 180 has a tapered outer surface 182 that fits inside of the elongated wall 154 of the first hub portion 150 to form a friction fit between the hub portions 150 and 152 and expands the flexible segments 164 of the first hub portion 150.

As seen in FIG. 8, the braking mechanism 112 is provided by meshing the teeth 130 and 148 of the outer and internal gear members 128 and 146. The gap 134 between the teeth 130 and 148 provides clearance for the teeth to slip or jump when the cable is pulled from the reel. The gear members 128 and 146 prevent overpayout of the cable. More specifically, when the cable is pulled from the reel, the flanges 106 and 108 rotate, thereby making the gear teeth 130, 148 rotate. The side support is preferably fixed inside of the supporting bag or box and therefore does not rotate. This causes the gear teeth 148 to override meshing gear teeth 130 on the side support which creates friction and provides a braking to the momentum of the reel if the cable is pulled too hard. This action also creates a clicking mechanism which in turn prevents overpaying the cable.

The distance of the gap need only be long enough to provide a clearance to have gear teeth 148 to override teeth 130, thereby allowing the braking mechanism to work. This clearance distance could vary depending upon the gear teeth depth, flange hole inner diameter, side support gear depth, and the outer diameter of the middle flange support 124. The gap 134 may be, for example, abut ¾ inch.

To install the cable on the cable reel 100, the cable coil C is placed over the first hub portion 150 of the hub member 110 and on the first flange 106 so that the first hub portion 150 extends through the inner diameter of the cable coil. The cable coil C may be prepacked in a plastic shrink wrap or with tie wraps or combination of both without any external structure to support that coil. Next the second hub portion 152 is inserted inside of the first hub portion 150 to frictionally engage the same and expand the flexible segments 164, thereby forcing the flexible segments 164 to engage the inner diameter of the cable coil. The locking tabs 174 are then inserted inside of the slots 176 on the second flange 108 to hold the two flanges and hub portions together.

In an example of the present disclosure, the first support frame 102 of the reel 100 is secured to the base of the bag or box, such as by straps, such as via strap 105 (FIG. 1), and the second support frame 104 is secured to the cover or flap of the bag. With the cable coil installed on the hub member 110, the cable coil is inserted into the bag or box between the support frames 102 and 104 in the bag or box. The assembly of the hub portions 150 and 152, the flanges 106 and 108, and the cable coil is preferably inserted into the base of the bag on its side such that the middle flange support 124 of the frame secured to the base of the bag fits inside of the central arbor opening 144 of the flange. Similarly, the middle flange support 124 of the frame secured to the cover of the bag fits inside of the opening 144 of the other flange when the bag is closed. Once the frames 102 and 104 are mated with the flanges 106 and 108, respectively, the operator can then dispense or payout the cable through a cable payout slot or opening in the bag or box. The operator may open the cover of the bag or box to separate the hub portions 150 and 152 by disengaging the snap tabs 174.

Referring now to FIG. 9, in some embodiments, a cable reel includes an axially adjustable coupling mechanism 284 between the first flange 206 and second flange 208. In particular, the first hub portion 250 and second hub portion 252 are coupled to one another by the axially adjustable coupling mechanism 284. For example, the first hub portion 250 and second hub portion 252 are coupled together along a rotational axis 286 around which the first flange 206 and second flange 208 rotate when in a cable reel assembly, such as that described in relation to FIG. 1 through FIG. 8. The axially adjustable coupling mechanism 284 allows the first hub portion 250 and the second hub portion 252, and therefore the first flange 206 and second flange 208, respectively, to be rotationally fixed to one another at a plurality of axial positions in the direction of the rotational axis 286.

In some embodiments, the axially adjustable coupling mechanism 284 includes a threaded connection between the first hub portion 250 and the second hub position 252. The axially adjustable coupling mechanism 284 includes a male threaded portion 288 and a complementary female threaded portion 290 on each of the first hub portion 250 and second hub portion 252 respectively, as shown in FIG. 10. In other embodiments, the male threaded portion 288 and the complementary female threaded portion 290 may be located in other configurations, such as the male threaded portion 288 and the complementary female threaded portion 290 positioned on the second hub portion 252 and the first hub portion 250, respectively.

The first flange 206 and the second flange 208 are configured to contain a coil of cable around the mated first hub portion 250 and second hub portion 252. In some instances, the cable coil can loosen or expand during shipping, during removal from packaging, during installation on the reel, or for other reasons. When the cable coil expands in a traverse direction (e.g., the axial direction of the rotational axis of the cable reel when the cable coil is on the cable reel), the cable coil may be unable to fit between the first flange and the second flange of some cable reels. A cable reel with an axially adjustable coupling mechanism 284 can, therefore, ease the installation of a cable coil when the coil has expanded during shipping, during removal from packaging, during installation on the reel, or for other reasons.

When a threaded connection is mated together, the first flange 206 and second flange 208 may apply an axially compressive force to the cable coil and/or the first hub portion may apply a radially expansive force to the cable coil. The resulting friction in the threaded connection and/or between the flanges 206, 208 and/or hub portions 250, 252 with the cable coil may secure the axially adjustable coupling mechanism 284. Because the flanges 206, 208 rotate relative to the support frames (such as those described in relation to FIG. 1) substantially freely, the axially adjustable coupling mechanism 284 may remain mated. In embodiments with a braking mechanism, the threads may be oriented in the rotational direction of cable feed from the coil, causing torque applied to the flanges 206, 208 while an installer pulls on the cable to feed out from the cable coil to further tighten the threaded connection.

Referring now to FIG. 11, in some embodiments, an axially adjustable coupling mechanism 384 includes a rotational ratcheting mechanism (e.g., ratcheting pawls 392 and a plurality of teeth 394) to limit and/or prevent the axially adjustable coupling mechanism 384 from becoming disconnected. The axially adjustable coupling mechanism 384 includes a threaded connection, similar to the structures described in relation to FIG. 10, with ratcheting pawls 392 supported by flexible arms 364 on the first hub portion 350. In some embodiments, the pawls 392 engage with a plurality of teeth 394 or recesses on the second hub portion 352 arranged rotationally around the second hub portion 352. As the threaded connection couples the first hub position 350 to the second hub portion 352, the ratcheting pawls 392 contact and engage with the teeth 394. The flexible arms 364 elastically deform and apply a radially compressive force to the teeth 394 and limit and/or prevent the first hub portion 350 and second hub portion 352 rotating relative to one another and the axially adjustable coupling mechanism 384 becoming disconnected.

It should be understood that the pawls 392 and teeth 394 may be arranged in other configurations to rotationally engage. For example, the pawls 392 may be supported by the second hub portion 352 and the teeth 394 located on the first hub portion 350. In some embodiments, the pawls 392 may be biased radially outwardly to apply a radially expansive force to teeth 394 oriented toward the rotational axis 386.

Referring now to FIG. 12, in some embodiments, an axially adjustable coupling mechanism 484 includes an axial ratcheting mechanism to limit and/or prevent the axially adjustable coupling mechanism 484 from becoming disconnected. The axially adjustable coupling mechanism 484 includes a threaded connection, similar to the structures described in relation to FIG. 10, with ratcheting pawls 492 supported by flexible arms 464 on the first hub portion 450. In some embodiments, the pawls 492 engage with a plurality of teeth 494 or recesses on the second hub portion 452 arranged axially on the second hub portion 452. As the threaded connection couples the first hub position 450 to the second hub portion 452, the ratcheting pawls 492 contact and engage with the teeth 494. The flexible arms 464 elastically deform and apply a radially compressive force to the teeth 494 and limit and/or prevent the first hub portion 450 and the second hub portion 452 from moving axially relative to one another and the axially adjustable coupling mechanism 484 becoming disconnected.

It should be understood that the pawls 492 and teeth 494 may be arranged in other configurations to axially engage. For example, the pawls 492 may be supported by the second hub portion 452 and the teeth 494 located on the first hub portion 450. In some embodiments, the pawls 492 may be biased radially outwardly to apply a radially expansive force to teeth 494 oriented toward the rotational axis 486.

While embodiments of axially adjustable coupling mechanisms with threaded connections have been described with the threads on the first hub portion and the second hub portion, in other embodiments, an axially adjustable coupling mechanism with a threaded connection includes a nut or other additional component to compress the first hub portion to the second hub portion.

FIG. 13 is a side cross-sectional view of an embodiment of a first hub portion 550 and a second hub portion 552 that are connected by an axially adjustable coupling mechanism 584 including a nut 596. In some embodiments, the male threaded portion 588 is positioned on the first hub portion 550 and the complementary female threaded portion 590 is positioned on the nut 596 opposite the second hub portion 552. A part of the first hub portion 550 may be inserted through the second hub portion 552 to engage with the nut 596. When the male threaded portion 588 on the first hub portion 550 engages with the complementary female threaded portion 590 positioned on the nut 596, the threaded connection compresses the second hub portion 552 against the first hub portion 550. In some embodiments, the second hub portion 552 and/or second flange 508 is configured to receive the nut 596 flush with a surface of the second hub portion 552 and/or second flange 508. The first flange 506 and second flange 508 may fit within the support frames of the reel when the nut 596 and second flange 508 form a flat outer surface.

Other embodiments of axially adjustable coupling mechanisms do not include threads, but rather rotationally and/or axially fix the first hub portion relative to the second hub portion through axially oriented splines. FIG. 14 is a detail cross-sectional view of an axially adjustable coupling mechanism 684 with axial splines 696. An axial spline 696 on the second hub portion 652 engages with an axial slot 698 on the first hub portion 650 and, alone, limits and/or prevents rotation of the first hub portion 650 and the second hub portion 652 relative to one another while allowing axial movement relative to one another.

In some embodiments, one or more radial protrusions 699 on flexible arms 664 of the first hub portion 650 may engage with one or more circumferential recesses 607 on the second hub portion 652. The engagement of the radial protrusion 699 and circumferential recess 607 alone limits and/or prevents axial movement of the first hub portion 650 and the second hub portion 652 relative to one another while allowing rotational movement relative to one another. When an axially adjustable coupling mechanism 684 includes both the spline(s) 696 and slot(s) 698 with the protrusion(s) 699 and recess(es) 607, the axially adjustable coupling mechanism 684 both rotationally and axially fixes the first hub portion 650 relative to the second hub portion 652. The flexible arms 664 supporting the protrusions 699 may elastically deform allowing an installer to press the first hub portion 650 and second hub portion 652 together and pull the first hub portion 650 and second hub portion 652 apart, while still providing sufficient force to prevent unintended decoupling.

FIG. 15 through FIG. 17 illustrate embodiments of axially adjustable coupling mechanisms that provide a plurality of discrete axial positions. FIG. 15 is a side cross-sectional view of an embodiment of a first hub portion 750 and a second hub portion 752 with an axial series of recesses 707-1, 707-2, 707-3. The recesses 707-1, 707-2, 707-3 of the second hub portion 752 are positioned in a series of sets of recesses 707-1, 707-2, 707-3. The first recesses 707-1 include a set of recesses at a first axial position. The first recesses 707-1 include a set of recesses at a first axial position. The first recesses 707-1 include a set of recesses at a first axial position. The each set of recesses 707-1, 707-1, 707-3 includes a plurality of recesses complementarily formed to the protrusions 799 of the axially adjustable coupling mechanism 784.

The axially adjustable coupling mechanism 784 includes a plurality of flexible snap arms 772 with protrusions 799 protruding radially therefrom. The arms are elastically deformable to apply a radially outward force to the urge the protrusions toward one of the sets of recesses 707-1, 707-2, 707-3 as the first hub portion 750 is urged toward the second hub portion 752. In some embodiments, the protrusions 799 engage with a set of the recesses 707-1, 707-2, 707-3 in sequence as the first hub portion 750 moves axially. The engagement of the protrusions 799 with each set of recesses 707-1, 707-2, 707-3 provides a series of stable axial positions for the first hub portion 750 relative to the second hub portion 752. For example, a stable axial position may be a low energy state. For instance, when a protrusion 799 is at a stable axial position in a recess 707-1, 707-2, 707-3, additional force is required to move the protrusion 799 from the recess 707-1, 707-2, 707-3. In another example, a stable axial position may include a position where the force required for a protrusion 799 to engage a recess 707-1, 707-2, 707-3 may be lower than the force required to remove the protrusion 799 from the recess 707-1, 707-2, 707-3.

The protrusions 799 engage with each set of recesses 707-1, 707-2, 707-3 to limit and/or prevent movement of the first hub portion 750 relative to the second hub portion 752 in both the axial and the rotational directions. In some embodiments, the protrusions have a ramped surface in an axial direction to allow the protrusions to move out of the sets of recesses 707-1, 707-2, 707-3 in the axial direction when sufficient force is applied by an installer. In some embodiments, the protrusions 799 are ramped in the direction of the second flange 708 to ease connection and/or ramped in the direction of the first flange 706 to ease removal. In some embodiments, a slope of the ramped surface may be different on a leading face than on a trailing face (e.g., a leading face may have a lower slope to facilitate a protrusion 799 engaging a recess 707-1, 707-2, 707-3 as the protrusion 799 slides toward the second hub 752 along and a trailing face may have a higher slope to facilitate the protrusion 799 remaining in the recess 707-1, 707-2, 707-3 as the protrusion 799 is pulled away from the second hub 752).

In some embodiments, protrusions positioned at a variety of axial positions can sequentially engage with a single set of recesses to provide a plurality of stable axial positions for an axially adjustable coupling mechanism. FIG. 16 is a side cross-sectional view of an embodiment of a first hub portion 850 and a second hub portion 852 with a plurality of protrusions 899-1, 899-2 at different axial positions. The protrusions 899-1, 899-2 are supported by flexible snap arms 872 of different or equal lengths with each set of protrusions 899-1, 899-2 at a terminal end of the flexible snap arms 872 or in an intermediate location between a base of the flexible snap arms 872 and the terminal end.

In some embodiments, the angular arc length of a protrusion 899-1, 899-2 is substantially equal to that of the recess 807 into which the protrusion 899-1, 899-2 engages. For example, a protrusion 899-1, 899-2 with an arc length of 10° around the rotational axis may fit into a recess 807 of approximately a 10° arc length. By having complementary arc lengths, the protrusion 899-1, 899-2 and recess 807 limit and/or prevent the rotational movement of the first hub portion 850 relative to the second hub portion 852. In some embodiments, the protrusion 899-1, 899-2 has an arc length less than that of the recess to relax manufacturing tolerances and ease engagement between the protrusion 899-1, 899-2 and the recess 807.

As the first hub portion 850 is urged toward the second hub portion 852, the flexible snap arms 872 contact an inner surface of the second hub portion 852 and elastically deform radially. The first set of protrusions 899-1 approach the set of recesses 807 in the second hub portion 852. When the first set of protrusions 899-1 align axially and rotationally with at least some of the recesses of the set of recesses 807, the first set of protrusions 899-1 may engage (due to an elastic restorative force from the flexible snap arms 872) with the set of recesses 807 at a first axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 850 relative to the second hub portion 852.

An installer may apply a force to further disengage the first set of protrusions 899-1 from the set of recesses 807 and urge the second set of protrusions 899-1 toward the set of recesses 807. In some embodiments, when the second set of protrusions 899-2 align axially and rotationally with at least some of the recesses of the set of recesses 807, the second set of protrusions 899-2 may engage (due to an elastic restorative force from the flexible snap arms 872) with the set of recesses 807 at a second axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 850 relative to the second hub portion 852.

FIG. 16 illustrates an embodiment of an axially adjustable coupling mechanism 884 with a plurality of flexible snap arms 872 of different lengths with protrusions 899-1, 899-2 located at a terminal end thereof. In other embodiments, at least one of the flexible snap arms has a plurality of protrusions to provide different stable axial positions for the axially adjustable coupling mechanism. For example, FIG. 17 is a side cross-sectional view of an embodiment of a first hub portion 950 and a second hub portion 952 with an axial series of protrusions 999-1, 999-2 on at least one flexible snap arm 972.

The first set of protrusions 999-1 are located at a first axial position on the flexible snap arms 972. The second set of protrusions 999-2 are located at a second axial position on the flexible snap arms 972. The two sets of protrusions 999-1, 999-2 are configured to engage with the set of recesses 907 in the second hub portion 952 when the first hub portion 952 and second hub portion 950 are urged toward one another.

When the first set of protrusions 999-1 align axially and rotationally with at least some of the recesses of the set of recesses 907, the first set of protrusions 999-1 may engage (due to an elastic restorative force from the flexible snap arms 972) with the set of recesses 907 at a first axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 950 relative to the second hub portion 952.

An installer may apply a force to further disengage the first set of protrusions 999-1 from the set of recesses 907 and urge the second set of protrusions 999-1 toward the set of recesses 907. In some embodiments, when the second set of protrusions 999-2 align axially and rotationally with at least some of the recesses of the set of recesses 907, the second set of protrusions 999-2 may engage (due to an elastic restorative force from the flexible snap arms 972) with the set of recesses 907 at a second axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 850 relative to the second hub portion 952.

While particular embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. It will be apparent to those skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings that modifications, combinations, sub-combinations, and variations can be made without departing from the spirit or scope of this disclosure. Likewise, the various examples described may be used individually or in combination with other examples. Those skilled in the art will appreciate various combinations of examples not specifically described or illustrated herein that are still within the scope of this disclosure. In this respect, it is to be understood that the disclosure is not limited to the specific examples set forth and the examples of the disclosure are intended to be illustrative, not limiting.

As used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents, unless the context clearly dictates otherwise. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “comprising,” “including,” “having” and similar terms are intended to be inclusive such that there may be additional elements other than the listed elements.

Additionally, where a method described above or a method claim below does not explicitly require an order to be followed by its steps or an order is otherwise not required based on the description or claim language, it is not intended that any particular order be inferred. Likewise, where a method claim below does not explicitly recite a step mentioned in the description above, it should not be assumed that the step is required by the claim.

It is noted that the description and claims may use geometric or relational terms, such as right, left, above, below, upper, lower, top, bottom, linear, arcuate, elongated, parallel, perpendicular, etc. These terms are not intended to limit the disclosure and, in general, are used for convenience to facilitate the description based on the examples shown in the figures. In addition, the geometric or relational terms may not be exact. For instance, walls may not be exactly perpendicular or parallel to one another because of, for example, roughness of surfaces, tolerances allowed in manufacturing, etc., but still be considered to be perpendicular or parallel.

CABLE REEL WITH AXIALLY ADJUSTABLE COUPLING MECHANISM

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)