PACKAGING FOR WOUND COIL

Abstract

A packaged wound coil assembly includes a coil of wire, a payout tube, two flat panels on either side of the coil of wire, and a retainer to secure the flat panels relative to the coil assembly. The package assembly uses significantly less materials than prior packages and as assembled can assume less overall space than prior packages for similar wire coils.

Description

BACKGROUND

1. Field

This application relates to packaging for a wound coil. More particularly, this application relates to packaging for a coil of cable, wire, or filaments that is adapted to be dispensed through a payout tube, although it is not limited thereto.

2. State of the Art

Coils that dispense from the inside-out without twists, tangles, snags or overruns are known in the art as REELEX-type coils. (REELEX is a trademark of Reelex Packaging Solutions, Inc.) REELEX-type coils are wound to form a generally short hollow cylinder with the ends of the cylinder extending radially outward beyond the radial extension of the middle of the cylinder, and with a radial opening formed at a location in the middle of the width of the cylinder. A payout tube may be located in the radial opening so that an inner end of the cable may be fed through the payout tube dispensing the cable, wire, or filaments (hereinafter, referred to collectively as wire) of the coil. This is in contrast to, e.g., coiled cable supported and packaged on a spool, in which the inner end of the coiled cable is fixed and the outer end of the coiled cable is released for dispensing as the spool is rotated. REELEX-type coils do not rotate when unwound, and consequently the coil does not depend on movement of the packaging itself to dispense the wire properly.

One known package for REELEX-type coils is a six-sided double flap cardboard box, with the box provided with a circular opening in the middle of the double flap side for receiving the payout tube. The cardboard box may also be provided with a hand-hold opening. Another known package for REELEX-type coils is a shrink-wrap package with a side opening for the payout tube and an integral top handle having a hand-hold opening.

SUMMARY

In an embodiment of the system, a packaging system is provided for a wound coil of wire. The wound coil of wire is preferably a REELEX-type wound coil. In another embodiment, the packaging system is for a wound coil of wire, but not inclusive of the coil of wire itself. Preferably, one or more layers of film are wrapped around the wound coil to keep the wound coil in the wound form after being removed from the coil winder. The film is preferably a polyethylene plastic wrap. A payout tube is provided having a hollow body and a flange. The body of the payout tube is positioned through the film and into a radial opening formed within the windings of the wound coil, and the flange of the payout tube is seated on the exterior of the film and wound coil. Alternatively, the payout tube may be inserted through the wound coil prior to the wrapping the wound coil in the film.

In accord with an aspect of the packaging system, the wound coil is not supported on a central spool in the packaging system. In accord with another aspect of the packaging system, a pair of generally flat panels are provided and positioned on opposite sides of the wound coil. The panels are preferably made from cardboard, but alternatively can be made from plastic, wood, or a wood by-product. In accord with yet another aspect of the packaging system, a retainer secures the panels to the coil. In embodiments, the retainer is a film wrap provided about the wound coil and at least the periphery of the flat panels to assemble the wound coil and surrounding pair of panels and film into the package of wound coil. The film wrap can be pierced to access the payout tube and draw an end of the coil from the payout tube in the packaging without removing the remainder of the film wrap. In other embodiments, the flat panels are retained relative to the coil with strapping under tension that extends about the coil and flat panels. The strapping may be used alone or in combination with the film wrap. Other than via the retainers of the film wrap and/or strapping, there is no connection between the panels, and the panels would separate from the wound coil if the retainer were completely removed.

The pair of flat panels may be any suitable shape. Preferably, though not necessarily, each panel of the pair can have at least one flat side at its periphery. The at least one flat side can be configured to rest on a floor or working surface to support the package (and the payout tube of the package) in a preferred orientation. By way of example, the panels can be hexagonal, square, in other polygonal shapes, or even round. When the panels have at least one flat side, it is preferable that they both be of common shape, though they can be differently shaped. The panels are preferably oriented relative to the payout tube such that the payout tube is angled upwards between horizontal and vertical when at least one flat side is seated on a ground (or other support) surface, and more preferably the payout tube angled upwards between 30° to 60° relative to horizontal. The panels may include slots for guiding and retaining the strapping.

The pair of panels can include one or more cutouts that define an integrated handle or hand-hold. The one or more cutouts can be ovals, rectangles, and an arrangement of a plurality of finger-size circles, or other suitable shapes. The panels may also include holes or other openings for mounting, manipulation, and dispensing of the panels onto and by assembly machinery, including for example, robots, during manufacture of the packaging.

The film wrap that surrounds the pair of panels is preferably made of polyethylene. The film wrap can have sufficient strength and stiffness to prevent inadvertent tearing and disassembly of the package under normal use. The strapping can be made of a plastic or other suitable materials.

The package and coil together comprise an assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded assembly view of a packaging system for a REELEX-type wound coil in accordance with the present disclosure.

FIG. 2 is an assembly view of the packaging system of FIG. 1.

FIG. 3 illustrates an exemplary use of the packaging system of FIGS. 1 and 2.

FIGS. 4 through 8 are perspective views of exemplary alternate embodiments of a packaging system for a REELEX-type wound coil.

FIG. 9 is a perspective view of another embodiment of a packaging system for a REELEX-type wound coil.

FIG. 10 is a perspective view of yet another embodiment of a packaging system for a REELEX-type wound coil.

FIG. 11 is a plan view of a cardboard cutout, adapted to be folded into a side panel of the packaging system of FIG. 10.

FIG. 12 is a partially folded view of the panel of FIG. 11.

FIG. 13 is a perspective view of the panel of FIG. 11 folded and glued to form the side panel of the packaging system of FIG. 10.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 is an exploded assembly view of a package 100 for a REELEX-type coil 10, and FIG. 2 is an assembled view of the same package 100.

As seen in FIG. 1, the coil 10 of cable, wire, or filament (hereinafter referred to broadly as “wire”) is wound to form a generally short hollow cylinder with the extremities or ends E of the cylinder extending radially outward beyond the radial extension of the middle of the cylinder. The term “cylinder” or “cylindrical” as used herein refers to solid and tubular forms having a circular cross-sectional shape and a substantially similar diameters (within 10%) at each of its ends E. The diameter D1 of the coil at the ends may be greater than the diameter D2 of the coil at a location in the middle of the cylinder.

The coil 10, once wound, is optionally wrapped in one or more thin layers of flexible non-adhesive, self-retaining film 12. The film 12 is wrapped around the wound coil 10 to assist in keeping the wound coil from unwinding after being removed from the winding apparatus. The film 12 is preferably a polyethylene plastic wrap. The REELEX-type wound coil 10 is wound in a manner that spaces apart the windings at a location to define a radial opening (not shown) for a payout tube 14. The payout tube 14 has a body portion 16 defining a wire pathway, and a flange 18. The body portion 16 may be at least partially structured by a tube, a conical portion, or struts. The body portion 16 is positioned through the film 12 and into the radial opening formed within the windings of the wounding coil, while the flange 18 is seated on the exterior of the film 12 and the wound coil 10. The coil 10 has a width “W” (i.e., the height of the short cylinder), and the payout tube 14 is located along the coil at a position of one-half the width W and oriented transverse to the width W. An inner end 20 of the wound coil is fed through the body portion 16 of the payout tube 14 and preferably resides outside the body portion or near the exit of the tube for ease of access to the wire for dispensing.

The package 100 includes a pair of panels 102, 104 positioned against opposite sides of the width W of wound coil 10, with the panels 102, 104 and wound coil 10 retained together with a film wrap 106. The panels 102, 104 are preferably completely flat; however, it is possible that portions of the panels could be folded inward and/or outward, provided that the folds do not impede the function described herein.

The panels 102, 104 are preferably made from cardboard, but alternatively can be made from plastic, wood, or a wood by-product. The pair of panels 102, 104 may be in any suitable shape that permits manufacture, shipping and use. Preferably, though not necessarily, the panels 102, 104 include at least one flat side 110 which provides the advantage of stabilizing the package 100 on a ground (or other supporting) preferably horizontal surface 112 (FIG. 3). By way of example, the panels can be hexagonal, as shown in FIGS. 2 and 3. The panels 102, 104 can be cut to hexagonal shape, or can edges folded to define the intended external peripheral shape. When the panels 102, 104 have at least one flat side, it is preferable that the panels be of a common shape, though they can be differently shaped. The panels 102, 104 are preferably oriented on the ends E of the wound coil 10 and relative to the payout tube 14 such that the payout tube 14 is angled upwards between horizontal H and vertical V when the respective flat side 110 is seated on the supporting surface 112, and more preferably the payout tube 14 is angled upwards between 30° to 60° relative to horizontal (FIG. 3) when supported on surface 112.

The pair of panels 102, 104 can include cutouts 114 that define an integrated handle or hand-hold. In a preferred embodiment, the cutouts 114 can extend through center of the panels 102, 104 and also the radial center of the wound coil 10. The cutouts 114 are preferably provided at both panels 102, 104, but alternatively can be provided to only a single panel. The cutouts 114 can be ovals, rectangles, and an arrangement of a plurality of finger-size circles, or other suitable shapes. The panels 102, 104 may also include holes 116 or other openings for mounting, manipulation, and dispensing of the panels onto and by assembly machinery, including for example, robots, during manufacture of the packaging.

The film wrap 106 is configured to extend across the width W of the wound coil 10 and surrounds a periphery of the panels 102, 104 to retain the wound coil 10 and panels 102, 104 into an integrated package. The film wrap 106 can be pierced over the opening of the payout tube 14 to access the payout tube and thereby pull out the wire end 20 of the wound coil 10 from the payout tube 14 while the remainder of the film wrap 106 is retained over the wound coil 10; i.e., without removing the remainder of the film wrap. The film warp 106 is preferably made of plastic (such as a polyethylene heat shrink film), and has a preferred thickness of 5 mils, but other thickness could be used. As an alternative to shrink film, the film wrap 106 can be a band of suitable plastic wrapped around the entire wound coil and panels, capturing the panels on either side of the coil, preventing the panels from separating from the coil and creating a package that completely encompasses the coil. Using the film wrap and the same size panels allows multiple wire sizes to use the same packaging materials. The film wrap 106 can have sufficient strength and stiffness to prevent inadvertent tearing and disassembly of the package under normal use.

Turning now to FIG. 3, in use, the package 100 is placed on a floor ground or working surface generally below the waist height of a user. The package 100 is supported with the side panels upright, and rotationally orientated on such that the payout tube is preferably angled upwards between 30° to 60° when supported. The package 100 preferably rests on the periphery of the side panels, and more preferably on parallel flat sides of the two panels. The film wrap 106 can be pierced over the body of the payout tube and the wire end 20 is accessed for dispensing. The remainder of the film wrap 106 preferably remains on the package 100 during dispensing. The wire end 20 is then drawn as needed from the wound coil.

In other embodiments, the package of FIGS. 1 to 3 can be assembled with panels of different shape than hexagonal. For example, as shown in FIG. 4, the panels 202, 204 can be generally round with a bottom flat 210 configured to rest on the floor ground or working surface. The bottom flat 210 can be configured to orient the payout tube in a preferred orientation (e.g., angled upwards between 30° to) 60° when the bottom flat 210 rests on the floor ground or working surface. In another example shown in FIG. 5, the panels 302, 304 can be square or another quadrilateral to with sides configured to rest on the floor ground or working surface. The sides can orient the payout tube in the preferred orientation. In other examples shown in FIGS. 6 and 7, the panels 402, 404 can be pentagonal (FIG. 6) or the panels 502, 504 can be octagonal (FIG. 7) in shape, or another polygonal shape which preferably stabilizes the package upright on the panels and/or orients the payout tube 14 in the preferred orientation. In another example shown in FIG. 8, the panels do not necessarily have to have a flat or straight side; the panels 602, 604 can be completely round; moreover, the sides can even have multiple curves, some convex, some concave. While various options with curved sides may have reduced stability, all will function as suitable packaging and permit appropriate dispensing of the wound coil. It is therefore appreciated that other variations to the package can be made.

Turning now to FIG. 9, another embodiment of a package assembly is shown. The coil 10 (shown in phantom) is optionally wrapped in one or more thin layers of flexible non-adhesive, self-retaining film (not shown). A payout tube 14 is positioned through the film and into a radial opening in the coil 10. A pair of side panels 702, 704 are positioned against the opposite sides of the width of wound coil 10. The panels 702, 704 and wound coil 10 are retained together in an assembly with at least one tension strap 750 that extends around the panels 72, 704 and the wound coil 10. The tension straps hereinafter are referred to in the plural (‘straps’), but could be a single strap wrapped that extends at least once about the diameter of the assembly, and optionally extends multiple times about the assembly. The tension straps 750 are preferably substantially inelastic; they may be made of plastic, such as polyester, but could also be made of steel or twine. The panels 702, 704 may include recesses 752 that guide the tension straps 750 down to the surface of the wound coil 10. This allows the panels 702, 704 to be used with coils 10 of various diameters while preventing the tension straps 750 from applying a radial or lateral force to the panels 702, 704 that would flex and/or deform them. A retaining film (not shown, but similar to the film wrap 106 described with respect to FIG. 1) can be applied over the coil 10, panels 702, 704, and strap assembly 750. The tension straps 750 keep the assembly centered until the retaining film is applied. Alternatively, the retaining film, if utilized, may be applied under the tension straps 750.

Referring now to FIG. 10, another embodiment of a package assembly is shown. The package assembly includes a pair of panels 802, 804 positioned against opposite sides of the width of wound coil 10. The coil 10 (shown schematically) is preferably wrapped in one or more thin layers of flexible non-adhesive, self-retaining film (not shown) and provided with a payout tube 14 radially toward a center of the coil to feed the wire of the coil from the inside out. The panels 802, 804 and wound coil 10 are retained together with a poly (plastic) band strapping 850 extending crosswise about the panels and wound coil and retained under suitable tension. A retaining film (not shown, but similar to the film wrap 106 described with respect to FIG. 1) may be optionally provided about the panels and coil, either over or under the strapping 850.

The panels 802, 804 are preferably substantially flat. In one exemplar embodiment, the panels 802, 804 have four sides 806, defining a generally square shape. Each of the sides 806 includes a bendably deformable central tab 840 with a recessed guide 842. The strapping 850 extends over the tabs 840 and through the guides 842, causing the tabs 840 to deform inward over the first and second sides 10a, 10b of the wound coil 10 to facilitate retaining the package assembly on the coil 10 when the strapping 850 is tensioned and secured at its ends. The panels 802, 804 preferably define a central opening 812 aligned with the center opening of the wound coil 10. The panels 802, 804 can also define angled corners 810. The corners 810 are preferably angled at 45° relative to their adjacent sides 806. Handle grips 814 can be defined in the panels, preferably in adjacent set of corners 810. In one embodiment, the payout tube 14 in the wound coil 10 is oriented upright, 90°±20° relative to the handle grips 814.

The panels 102, 104 can be made from a multi-ply cardboard. In an embodiment, the starter component 860 of a panel 802 can be stamped from a single or other ply cardboard in a shape as shown in FIG. 11. The starter component 860 includes four sub-panels 802a, 802b, 802c, 802d, each substantially corresponding to the shape of the panel 802 but which are attached to each other in a side-by-side arrangement along hinged edges 805a, 805d, 805c. The subpanels 802am 802b, 802c, 802d are folded relative to each other along the hinged edges 805a, 805b, 805c, 805d as shown in FIG. 12. During or prior to the folding process, and before the adjacent faces of the subpanels contact each other, the adjacent faces of the subpanels can be coated with a glue or other suitable adhesive. Then, when the adjacent faces of the subpanels 802a, 802b, 802c, 802d are placed into contact, they are permanently joined together into the multi-ply panel 802 of FIG. 13, which is a component of the packaging assembly.

The various embodiments of a packaging assembly as described herein are advantageous because the packaging assembly uses significantly less materials than prior packages and assumes less overall space than prior packages for REELEX-type coils, while maintaining all of the advantages when dispensing coil from a REELEX-type coil; i.e., linear dispensing without rotation of the wound coil and without imparting twists, tangles, snags or overruns.

There have been described and illustrated herein several embodiments of a package or packager assembly for a coil, and a packaged coil. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular materials, dimensions, and capacities for the package have been disclosed, it will be appreciated that other materials, dimensions and capacities may be used as well. As such, any of the panels can be alternatively made of cardboard, wood, wood by-product, plastic, as well as other suitable materials. In addition, while the strapping is preferably plastic band strapping that can be tensioned by hand, tool, or machine, it is appreciated that the strapping can be any suitable longitudinal tensile loading element, including steel strapping, cable, wire, twine, cord, tape, reinforced paper, fabric or other materials. Further yet, while the package or package assembly has been described with particular reference to a REELEX-type coil, it will be understood that the package or package assembly is useful for other types of coils. For purposes herein, the term “retainer” shall be used in reference to any structure or device suitable to securing the two side panels relative to the coil in accord with the description herein, and equivalents thereof. Also, while in various embodiments, the cling wrap is stated to be positioned around the wound coil prior to inserted the payout tube into the coil, it is recognized, appreciated and within variants of any of the embodiments that the payout tube may be inserted into the wound coil prior to wrapping the coil with the cling wrap. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.

Claims

1. A packaged wound coil assembly, comprising: a coil of wire, the coil of wire having an outer diameter and a wound coil width extending between first side and a second side;a payout tube having a longitudinal axis extending into the wound coil; anda first panel and a second panel on the first and second sides of the coil, the first and second panels each having a periphery; andretention means for securing the first and second panels to the coil.

2. The assembly of claim 1, wherein: the retention means includes a film wrap extending over the coil across the width of the coil and over at least the periphery of each of the first and second panels.

3. The assembly of claim 2, wherein: the film wrap is a shrink wrap film.

4. The assembly of claim 1, wherein: the retention means includes a strapping extending across the width of the coil and over each of the first and second panels.

5. The assembly of claim 4, wherein: the strapping is poly band strapping.

6. The assembly of claim 4, wherein: each of the first and second panels defines recesses into which the strapping extends.

7. The assembly of claim 1, wherein: the retention means includes both of (i) a film wrap extending over the coil across the width of the coil and over at least the periphery of each of the first and second panels, and (ii) a strapping extending across the width of the coil and over each of the first and second panels.

8. The assembly of claim 1, wherein: the periphery of the first panel has a non-round periphery.

9. The assembly of claim 8, wherein: the periphery of the first panel is polygonal in shape.

10. The assembly of claim 1, wherein: the first panel includes at least one cutout defining a hand-hold.

11. The assembly of claim 10, wherein: the at least one cutout extends through a center of the first panel.

12. The assembly of claim 10, wherein: the at least one cutout extends adjacent a corner of the first panel.

13. The assembly of claim 1, wherein: the coil defines an opening between windings of the wire, the payout tube includes a body and a flange, and the body extends into the opening and the flange seats adjacent an exterior of the coil.

14. The assembly of claim 1, further comprising: a film that extends about at least a portion of the coil of wire.

15. A packaged wound coil assembly, comprising: a coil of wire, the coil of wire having an outer diameter and a wound coil width extending between first side and a second side;a payout tube having a longitudinal axis extending into the wound coil; anda first panel and a second separate and discrete panels on the first and second sides of the coil, the first and second panels each having a periphery; anda retainer extending over the coil that secures the first and second panels to the coil of wire in a manner that permits the wire to be dispensed from the coil through the payout tube while the retainer continues to secure to the first and second panels relative to the coil.

16. A wound coil package assembly, comprising: a coil of wire, the coil of wire having an outer diameter and a wound coil width extending between a first side and a second side, the coil of wire defining windings;a payout tube having a longitudinal axis extending radially into the coil of wire between the first side and the second side;a first and second separate and discrete panels located on the first and second sides of the coil of wire, the first and second panels each having a periphery; anda film wrap extending over the coil of wire across the width of the coil of wire and over at least the periphery of the first and second panels to retain the film wrap and first and second panels relative to the coil of wire.

17. The assembly of claim 16, wherein: the peripheries of each of the first and second panels are non-circular.

18. The assembly of claim 16, wherein: at least the first panel defines a hand-hold.

19. The assembly of claim 16, wherein: the film wrap is a heat shrink film.

20. The assembly of claim 16, further comprising: a film that is separate from the film wrap and extends about at least a portion of the coil of wire.

21. A wound coil package assembly, comprising: a coil of wire, the coil of wire having an outer diameter and a wound coil width extending between a first side and a second side, the coil of wire defining windings;a payout tube having a longitudinal axis extending radially into the coil of wire between the first side and the second side;a first and second separate and discrete panels located on the first and second sides of the coil of wire, the first and second panels each having a periphery; andstrapping extending over the coil of wire across the width of the coil of wire and over the first and second panels to retain the first and second panels relative to the coil of wire.

22. The assembly of claim 21, wherein: the peripheries of each of the first and second panels are non-circular.

23. The assembly of claim 21, wherein: at least the first panel defines a hand-hold.

24. The assembly of claim 21, wherein: the first and second panels define movable tabs with guides, and the strapping extends over the tabs and through the guides, causing the tabs to deform inward over the first and second sides of the coil of wire.

25. The assembly of claim 21, further comprising: a film that extends about at least a portion of the coil of wire.

26. A wound coil package assembly, comprising: a coil of wire, the coil of wire having an outer diameter and a wound coil width extending between a first side and a second side, the coil of wire defining windings;a payout tube having a longitudinal axis extending radially into the coil of wire between the first side and the second side;separate and discrete first and second panels located on the first and second sides of the coil of wire, the first and second panels each having a periphery;strapping extending about the first and second panels and the coil to retain the first and second panels relative to the coil; anda film wrap extending over the coil of wire across the width of the coil of wire and over at least the periphery of the first and second panels to retain the film wrap and first and second panels relative to the coil of wire.

27. The assembly of claim 26, wherein: each of the first and second panels defines guides into which the strapping extends.

28. The assembly of claim 26, further comprising: a film that is separate from the film wrap and extends about at least a portion of the coil of wire.

29. A method of dispensing wire, comprising: a) providing a packaged coil of wire including, a coil of wire defining windings extending between first and second sides of the coil of wire,a payout tube extending radially into the coil of wire between the windings,a first panel and a second panel on the first and second sides of the coil of wire, the first and second panels each having a periphery, andretention means securing the first and second panels relative to the coil;b) positioning the packaged coil of wire on a working surface supported by the first and second panels and with the payout tube oriented between horizontal and vertical; andc) pulling the wire out of the package through the payout tube.

30. The method of claim 29, wherein: the first and second panels are discrete from each other, flat, and define a non-round shape.

31. The method of claim 29, wherein: the retention means includes a film wrap that extends over the coil of wire and about the peripheries of the first and second panels, the method further including:piercing the film wrap over the payout tube to permit the wire to be dispensed from the coil out through the payout tube.

32. The method of claim 29, wherein: the retention means includes a strapping extending across the width of the coil and over each of the first and second panels.