This disclosure relates generally to apparatus for supporting wound flexible media, for example, cord, cable, fiber or wire.
The transport and use of cable, wire, optical fiber, and other wound media typically involves winding the flexible media on a spool or reel. Typical reels for construction purposes can have a traverse length (or axial height) of any length, and any flange diameter. Reels generally consist of a core around which the wound media is wrapped, and two flanges at opposite ends of the core. Such reels can be made of wood, but are often constructed of plastic and/or corrugated paper to obtain better strength-to-weight ratios. Reels further more often include steel bolts, staples, or other connectors. Such reels have many good features, but can present difficulties in recycling due to the use of different materials. Recycling used reels is a feature that can lead to reduced landfills, and overall environmental improvements.
There is a need, therefore, for a reel design that is sustainable and facilitates recycling while maintaining sufficient structural integrity for normal use
In one embodiment, a reel includes a core, a first flange, a first collar, and a first locking arrangement having a locked configuration in which a first end region of the core, the first flange, and the first collar are connected to one another, and an unlocked configuration in which the first end region of the core, the first flange, and the first collar are disconnected from one another. The first locking arrangement is movable between the unlocked configuration and the locked configuration.
In another embodiment, a method of connecting a core, a first flange, and a first collar of a reel to one another includes moving a first locking arrangement from an unlocked configuration, in which a first end region of the core, the first flange, and the first collar are disconnected from one another, to a locked configuration in which the first end region of the core, the first flange, and the first collar are connected to one another.
Flexible media, not shown, but which can include cable, wire, fiber optical cable, rope, string, etc., can be wound around the core 104 and axially retained on the core by the flanges 108, 116. As will be discussed in further detail below, each of the collars 112, 120 has features that interact with corresponding features on the respective flange 108, 116 and corresponding features of the core 104 in a locked configuration to securely connect the flange 108, 116 to the core 104. These features of the respective collar 112, 120 and the corresponding features on the respective flange 108, 116 and the core 104 are collectively referred to herein as a locking arrangement 132 or a rotating locking arrangement.
In the illustrated embodiment, the flanges 108, 116, the collars 112, 120, and the respective locking arrangements 132 are substantially identical at each end of the core 104. The following description therefore only describes one of the flanges 108, collars 112, and locking arrangements 132, though the reader should appreciate that the flange 116, collar 120, and locking arrangement 132 at the opposite end of the core 104 is substantially identical.
The core 104 is formed of a hollow cylindrical body 140 having a plurality of windows 144 defined radially through the cylindrical body 140 at each end region of the hollow cylindrical body 140. In the illustrated embodiment, the core 104 includes three windows 144 equally spaced around the circumference of the body 140 at each end of the core 104, though the reader should appreciate that any desired number of windows 144 may be used in other embodiments and, further, in some embodiments the windows 144 may be irregularly spaced around the circumference of the body 140.
The flanges 108, 116 are generally disk-shaped, with an inner side 160 (i.e. the side facing toward the opposite flange) being substantially flat and an outer side 164 including a plurality of radially and circumferentially extending structural ribs. The flanges 108, 116 have a central hub portion 168, which is illustrated in more detail in
With reference to
Within the first annular channel 196, a plurality of slots 212 are defined through the entire thickness of the flange 108, 116. In the illustrated embodiment, there are three slots 212, though the reader should appreciate that the number of slots 212 may vary in other embodiments. In some embodiments, the number of slots 212 is equal to the number of windows 144 of the core 104. In addition, at or near one end of each of the plurality of slots 212, an axial recess 216 is defined radially into the second circular wall 180 extending entirely through the axial thickness of the flange 108, 116.
Further, within the slot 212, a radial bump 220 extends radially inwardly from the second circular wall 180 into the first annular channel 196 at a position spaced apart from the end of the slot 212 opposite the recess 216. In one embodiment, the radial bump 220 extends through the entire axial thickness of the second circular wall 180. While the axial recess 216 and the radial bump 220 are both formed in the second circular wall 180 in the embodiment of
The hub portion 168 further includes a plurality of elongated wedge-shaped locking members 232, which form a flange feature of the locking arrangement 132, spaced around the circumference of the second annular channel 200 in the outer radial portion of the second annular channel 200. In particular, the number of locking members 232 is equal to the number of windows 144 in the core 104 so that, as will be discussed in detail below, each of the locking members 232 can engage in one of the windows 144 to lock the core 104 to the flanges 108, 116. The locking member 232 has a proximal end 236, which is connected to the third circular wall 184 and/or to the base of the second annular channel 200, and a distal end 240, which is wider than the proximal end 236 and is cantilevered from the proximal end 236. As a result, the distal end 240 is free to pivot about the proximal end 236 so that the distal end 240 is movable in the radial direction. In one embodiment, the locking member 232, and particularly the proximal end 236 thereof, is elastically flexible so as to enable the distal end 240 of the locking member 232 to pivot about the proximal end 236, though in other embodiments the proximal end 236 may include a pivoting joint to enable the pivoting of the distal end 240 about the proximal end 236.
Additionally, the hub portion 168 defines a plurality of wedge-shaped openings 244, each of which is slightly larger than an associated one of the locking members 232 and extends through the entire axial thickness of the hub portion 168 at the location of the locking member 232. The wedge-shaped openings 244 facilitate injection molding of the locking members 232 by allowing for a seal-off insert with draft angles to be used to form the underside of the locking members 232. In some embodiments, however, the hub portion 168 does not include the wedge-shaped openings 244
Adjacent to each of the locking members 232, a circumferential gap 248, 252, respectively, is defined in each of the third and fourth circular walls 184, 188. Each circumferential gap 248, 252 has a length in the circumferential direction that is approximately the same as the circumferential length of the associated locking member 232 such that the locking member 232 is able to pivot into at least the circumferential gap 248 and be positioned partially in the third annular channel 204. Additionally, the circumferential gap 248 of the third circular wall 284 may have a chamfered edge 256 adjacent to the proximal end 236 of the locking member 232 to allow the locking member 232 to elastically deform into the gap 248 without interference from the third circular wall 184.
Referring now to
The collars 112, 120 also include a plurality of axial pins 332 projecting axially from the inner side 304 of the disk 300. The number of the pins 332 is, in particular, equal to the number of the slots 212 in the first annular channel 196 of the hub portion 168, and the circumferential spacing of the pins 332 is substantially the same as the circumferential spacing of the slots 212. Likewise, the axial pins 332 are located at a radial position that aligns with the radial position of the slots 212 in the hub portion 168. Each of the pins 332 has an axial length that is greater than the axial distance by which the circular projection 312 and the tabs 320 extend from the inner side 304 of the disk 300. For example, the pins 332 may have an axial length that is from 150% to 200% of the axial distance by which the circular projection 312 and the tabs 320 extend from the disk 300. Each of the axial pins 332 has a generally cross-shaped or plus-shaped cross-section. At the distal end of the axial pins 332, a rounded bump 336 extends radially outwardly from the pins 332. The rounded bump 336 has a flat surface 340 oriented generally parallel to and facing toward the surface of the inner side 304 of the disk 300.
The disk 300 also includes a plurality of through holes 344. In one particular embodiment, the plurality of through holes 344 includes two through holes 344 arranged symmetrically and on opposite sides of the disk 300. The through holes 344 may, in one embodiment, be designed to be engaged by a conventional spanner wrench to apply torque to the disk 300. The through holes 344 may be of any suitable shape or size to aid in the engagement of the disk 300 for rotation of the disk 300.
Now, the operation of locking arrangement 132 between the core 104, flanges 108, 116, and collars 112, 120 will be described with particular reference to
At the beginning of the method 500, the locking arrangement 132 is in the unlocked configuration (i.e.
Next, the collar 112 is placed onto the hub portion 168 of the flange 108 and aligned such that the axial pins 332 line up with the slot 212, and more specifically, the rounded radial extension 336 of the pins 332 align with the axial recess 216 in the second circular wall 180. The collar 112 is then pressed toward the flange 108 such that the radial extension 336 passes axially entirely through the axial recess 216 (block 520). At this point, slight rotation of the collar 112 relative to the flange 108 about the central axis 192 results in the flat surfaces 340 of the radial extensions 336 engaging the surface of the inner side 160 of the flange 108, as shown in the mostly locked configuration illustrated in
As seen in
The collar 112 is then rotated further relative to the flange 108 in the direction shown by the arrows 360 in
At the same time, the circular projection 312 and the radial tabs 320 move along the inner radial surface of the locking members 232 from the proximal end 236 to the distal end 240. As a result, the radial tabs 320, supported by the circular projection 312, exert a force in the radially outward direction on the locking members 232. The locking members 232 are thus caused to pivot about their respective proximal end 236 by, for example, elastically deforming, such that the outer radial portion of the distal end 240 of each of the locking members 232 moves first into the associated circumferential gap 248 in the third circular wall 184, and then into the associated window 144 of the cylindrical body 140 of the core 104, as seen in the illustration of the locked configuration shown in
The locking members 232 therefore axially engage both the windows 144 of the core 104 and the third circular wall 184 of the flange 108. As a result, the locking members 232 lock the flange 108 and the core 104 together so as to disable axial movement of the flange 108 relative to the core 104. Further, the distal end 240 of the locking members 232 also engages both the windows 144 of the core 104 and the third circular wall 184 in the circumferential direction to limit or disable rotational movement of the flange 108 relative to the core 104.
The collar 112 remains captively connected to the flange 108 in the axial direction by the engagement between the flat surfaces 340 of the radial extensions 336 of the axial pins 332 with the surface of the inner side 160 of the flange 108. Moreover, the axial pins 332 are rotationally fixed between the end surface of the slot 212 and the radial bump 220 such that the collar 112 cannot rotate relative to the flange 108. As a result, in the locked configuration, the locking arrangement 132 fixes the collar 112 relative to the flange 108 via the axial pins 332 and the flat surfaces 340 thereof, and fixes the flange 108 relative to the core 104 via the engagement of the locking members 232 with the windows 144 of the core 104.
Assembly of the reel 100 is then completed by attaching the flange 116 and collar 120 to the opposite end of the core 104 in the same manner as the flange 108 and collar 112 described above. The reader should appreciate that, while in the illustrated embodiment the opposite end of the core 104 is attached to the flange 116 using the same locking arrangement 132, in other embodiments the opposite end of the core 104 may be connected to the flange 116 using a different arrangement.
To disassemble the reel 104, the collar 112 can be rotated in the direction opposite the arrows 360 with sufficient force to cause the axial pin 332 to cause elastic deformation of the second circular wall 180, thereby moving the radial bump 220 out of the path of the axial pin 332. Once the radial extensions are 336 are aligned with the axial recesses 216, the core 104 and flange 108 can be separated from one another, and the collar 112 can be moved axially to remove the collar 112 from the flange 108.
The locking arrangement 132 according to the disclosure enables the reels 100 to be assembled and disassembled in a simple manner. As a result, the reels 100 can be shipped disassembled, and the end user is able to assemble the reels 100 with minimal effort. Accordingly, shipping and delivery costs can be reduced compared to pre-assembled reels.
Moreover, in conventional reel assemblies, the flanges are connected to the core by bolts, which necessitates using a high strength material, usually paper fiber, in the core to obtain sufficient strength for the bolted connection. The fibers from the paper, however, can shed from the core and cause damage to the flexible media on the reel, particularly to wires or cables. Moreover, the paper fibers can cause problems with sensitive equipment, particularly when used in sterile environments such as, for example, server rooms.
In contrast, the locking arrangement 132 according to the present disclosure requires no bolts, and can therefore be made entirely from plastic. In particular, in some embodiments, the entire assembled reel 100 may be formed of plastic material, particularly injection molded plastic or extruded plastic that is subsequently laser cut or die cut. As a result, the reel 100 does not have any paper fibers that can causes problems with the wire or other media. Moreover, because the reel 100 is formed entirely of plastic, there is no material that could cause contamination when used in sterile environments.
Furthermore, in some embodiments, the entire reel 100 may be formed of a single plastic material. Accordingly, since the entire reel 100 is formed of the same material, the entire assembled reel 100 can be recycled as a unit. As a result, the reel 100 can be recycled as-assembled, without the need for separating portions of the reel 100 made from different materials.
It will be appreciated that the above-described embodiments are merely illustrative, and that those of ordinary skill in the art may readily devise their own modifications and implementations that incorporate the principles of the present invention and fall within the spirit and scope thereof.
This application claims priority to U.S. Provisional Application Ser. No. 63/498,880 entitled “Flexible Media Reel with Rotating Locking Arrangement” filed Apr. 28, 2023, the disclosure of which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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63498880 | Apr 2023 | US |