Patent Grant
9556000
The present invention generally relates to a reel assembly. More particularly, the present invention relates to an interlocking structure for repeatedly securing a flange blank to a core blank in a reel configuration.
Reels and reel assemblies are commonly used to store and transport elongate lines of flexible material (e.g., wires, cables, ropes, cords, etc.), but their three-dimensional structure is inconvenient when unused. Unused reels can be difficult to store, and treating reels as disposable goods (i.e., discarding them after each use) can be uneconomical. Conventional reel assemblies are often made of wood material, which is heavy, requires mechanical fasteners, and is not moisture resistant. It is desirable to have reels that can be reusably disassembled from their three-dimensional reel configurations for easy storage.
Certain conventional reel assemblies have been made from lighter weight materials such as papers, plastics, etc. These are initially assembled from multiple slabs of material (each, broadly, a “blank”). Adhesives are commonly used to secure blanks in respective positions of a reel configuration. Though adhesives may be sufficiently strong to secure some blanks in reel configurations, they do not permit easy disassembly without damaging the blanks.
For improved reusability, some reel assemblies have used sets of blanks having corresponding interlocking structural features that can be used to secure the blanks together in a reel configuration. However, these sets of blanks suffer from various limitations. For example, in some cases the interlocking structural features provide insufficient strength to set of blanks in the reel configuration under the strain of the static and dynamic forces of the items stored on the reel in use. Likewise, in some cases, the very use of the interlocking structural features causes damage thereto, rendering the set of blanks incapable of reuse after disassembly.
One example of an interlocking structural feature that suffers from these limitations is a dart-type lock. Dart-type locks typically include an opening and a corresponding dart tab configured to be lockingly received in the opening. The dart tab typically has a widthwise span that is slightly wider than the width of the opening. The widthwise span of a typical dart tab is oriented substantially orthogonal to the longitudinal axis of the dart panel. As the name suggests, the front edge of a dart tab is tapered to a point. A force is applied generally in the direction of the longitudinal axis of the dart tab to insert the dart tab into the opening. As the front edge (i.e., the point) of the dart tab is inserted further into the opening, the widthwise span is increasingly compressed by the constraints of the narrower opening. This makes dart-type tags difficult to use in reel assemblies. Though the dart tab may show some widthwise resilience once it is received in the opening (e.g., the widthwise span may return to a width wider than that of the opening), the act of insertion tends to damage the dart tab. Likewise, the act of pulling the dart tab out of the opening tends to inflict additional damage to the dart tab. The damage inflicted by inserting and removing the dart tab through the opening can permanently deform the dart tab such that its widthwise span becomes permanently narrower than the width of the opening. When this occurs, the dart-type lock becomes inoperable. As a result, dart-type locks are not well-suited for frequent reuse as an interlocking structure in a reel assembly.
Reusability is also hampered in reel assemblies designed to carry heavy loads. Heavy loads require stronger structural elements. For example, the core component of a reel must be designed with sufficient strength to carry heavy loads. Prior reel assemblies capable of carrying heavy loads are not known to disassemble into constituent planar parts.
Accordingly, a reel assembly with improved reusability is desired.
An aspect of the present invention includes a set of blanks for being repeatedly assembled into a reel configuration. A flange blank comprises an inwardly and an outwardly facing major surface, a plurality of pass through slots angularly spaced apart from one another about a transverse axis of the flange blank, and a plurality of interlocking apertures angularly aligned with the plurality of pass through slots. Each pass through slot is spaced apart radially from a corresponding one of the interlocking apertures. Each of the pass through slots has a pass through width, and each of the interlocking apertures has an interlocking width. The pass through width is wider than the interlocking width. A core blank comprises a hub portion having a longitudinal body comprising opposite lateral ends. The hub portion is configured to be folded toward a core configuration in which the hub portion has an annular shape. A plurality of push tabs are foldably attached to and extend outwardly from one of the opposite lateral ends of the hub portion. Each of the plurality of push tabs is configured to pass through a respective one of the pass through slots and be lockingly received in a respective one of the interlocking apertures when the hub portion is arranged in the core configuration. Each push tab comprises a spine and a pair of wings extending outwardly from the spine. The wings of each of the push tabs are configured to bend away from a coplanar position with respect to their respective spine as each push tab is being inserted in a respective one of the plurality of interlocking apertures. The wings of each of the push tabs are further configured to lockingly engage the inwardly facing major surface of the flange blank adjacent the respective one of the plurality of interlocking apertures when each push tab is lockingly received in the respective one of the plurality of interlocking apertures.
Another aspect of the present invention includes an interlocking structure for repeatedly securing a flange blank to a core blank in reel configuration. The flange blank has an inwardly facing major surface, a pass through slot, and an interlocking aperture. A lateral end of the core blank is configured to engage the inwardly facing major surface of the flange blank when the flange blank and the core blank are secured in the reel configuration. A push tab is foldably attached to and extends outwardly from the lateral end of the core blank and is configured to pass through the pass through slot and be lockingly received in the interlocking aperture. The push tab comprises a spine and a pair of wings extending outwardly from the spine. The wings of the push tab are configured to bend away from a coplanar position with respect to the spine as each push tab is being inserted in the interlocking aperture. The wings of the push tab are further configured to lockingly engage the inwardly facing major surface of the flange blank adjacent the interlocking aperture when each push tab is lockingly received therein.
Another aspect of the present invention includes a core blank for being repeatedly secured in a core configuration in a reel assembly. The core blank comprises a one-piece slab of fluted material. The slab comprises a pair of spaced apart sheets of plastic material held in spaced apart relationship by a plurality of spaced apart plastic ribs. The plurality of plastic ribs define a plurality of flutes. Each of the plurality of flutes has a longitudinal axis. The longitudinal axes of the plurality of flutes are oriented parallel to one another. A hub portion has a longitudinal body comprising opposite lateral ends. The hub portion comprises a plurality of core joints extending between the opposite lateral ends of the hub portion and defining fold lines in the hub portion transverse to the longitudinal axes of the plurality of flutes. Each of the plurality of core joints comprises a line along which the plastic sheets of the one-piece slab are sealed against one another. The hub portion is configured to be folded along the fold lines of the core joints toward a core configuration in which the longitudinal body has an annular shape.
Other objects and features will be in part apparent and in part pointed out hereinafter.
Corresponding reference characters indicate corresponding parts throughout the drawings.
Referring to
In
Referring to
The flange blank 24 further includes ten interlocking apertures 42. Each of the interlocking apertures 42 is angularly aligned with a respective one of the pass through slots 40. Each pass through slot 40 is spaced apart radially outwardly from a corresponding one of the interlocking apertures 42. It is contemplated that, in other embodiments, pass through slots may be spaced apart radially inwardly from corresponding interlocking apertures without departing from the scope of the invention. In the illustrated embodiment, the interlocking apertures 42 are each spaced apart from the transverse axis the same radial distance (e.g., a radial distance less than the radial distance at which each of the pass through slots 40 are spaced from the transverse axis), and neighboring ones of the interlocking apertures are spaced apart from one another the same angular dimension (e.g., the same angular dimension at which neighboring ones of the pass through slots are spaced apart from one another). Between each interlocking aperture 42 and a respective one of the pass through slots 40 is a support portion 43 of the flange blank 24. Though the illustrated flange blank includes ten interlocking apertures 42, it should be understood that other flange blanks may include more or fewer interlocking apertures without departing from the scope of the invention. Like the pass through slots 40, the interlocking apertures 42 are each, along with other interoperable features of the reel assembly 20, constituent elements of respective interlocking structures 26.
The illustrated pass through slots 40 each have the same pass through width WPT. In other embodiments, pass through slots may have varying pass through widths without departing from the scope of the invention. The illustrated interlocking apertures each have the same interlocking width WI. It is further contemplated that, in some embodiments, interlocking apertures may have varying interlocking widths without departing from the scope of the invention. For corresponding pairs of pass through slots 40 and interlocking apertures 42, the pass through width WPT is greater than the interlocking width WI. Each of the illustrated pass through slots 40 has a substantially constant length along its pass through width WPT. The widthwise ends 40A, 40B of the pass through slots are rounded to improve the strength and durability of the pass through slots 40. Each of the interlocking apertures 42 has an interlocking length LI. A radially outward portion 44 of each interlocking aperture 42 has a substantially constant width WI. However, a radially inward portion 46 of each interlocking aperture 42 (that is radially inward of the flange blank 24) has a rounded end 48. In the illustrated embodiment, the rounded end 48 of each of the interlocking apertures 42 is rounded across its entire width. Thus, the interlocking apertures 42 each have a radially inward rounded end 48 with an arcuate shape (various embodiments may have radially inward rounded ends that are, e.g., semicircular, parabolic, etc.). As will be discussed in greater detail below, the shape of the rounded ends 48 of the interlocking aperture 42 improves the strength and durability of the flange blanks 24 and the interlocking structures 26.
Though
As shown best in
As will be discussed in greater detail below, the core blank 22
In addition to the hub portion 50, the core blank 22 comprises a plurality of push tabs, generally indicated at 60. As will be discussed in greater detail below, each of the push tabs 60 is, along with other interoperable features of the reel assembly 20, a constituent element of a respective interlocking structure 26. More specifically, each of the push tabs 60 is configured to be lockingly inserted in a respective one of the plurality of interlocking apertures 42 of a flange blank 24. Each of the plurality of push tabs 60 is attached to and extends outwardly from a respective one of the lateral ends 52 of the hub portion. In the illustrated embodiment, ten push tabs 60 extend laterally outward from each of the lateral ends 52 of the hub portion 50. The ten push tabs 60 on each lateral end of the hub portion 50 are spaced apart from one another along an axis parallel with the longitudinal axis of the hub portion. In the illustrated embodiment, the ten push tabs 60 along one lateral end 52 of the hub portion 50 are aligned with the ten push tabs on the other lateral end. As described in further detail below, each of the plurality of push tabs 60 is configured to pass through a respective one of the pass through slots 40 and be lockingly received in a respective one of the interlocking apertures 42 when the hub portion 50 is arranged in the core configuration. Due to the alignment on the push tabs 60 along respective lateral ends of the hub portion 50, when each of the push tabs is locked into a respective flange blank 24 (e.g., using respective pass through slots 40 and interlocking apertures 42), the pair of flange blanks 24 are angularly aligned with one another (e.g., their center axis holes 38 and each of their pass through slots and interlocking apertures are aligned with one another) when the reel assembly 20 is arranged in the reel configuration.
As shown best in
As mentioned above, a pair of wings 64 extends outwardly from the spine 62 of each push tab 60. More specifically, each illustrated wing 64 extends outward in a direction generally parallel to the longitudinal axis of the hub portion 50 from a respective interlocking portion 70 of the spine 62. Each of the push tabs 60 includes fold joints 73 (i.e., wing-adjacent fold joints) between each of its wings 64 and its spine 62. In the illustrated embodiment the wings 64 are each foldably attached to a respective interlocking portion 70 of the spine 62 at one of the fold joints 73.
In the illustrated embodiment, each of the push tabs comprises an interlocking body, generally indicated at 74. Each interlocking body 74 has an outer end 76 and a pair of interlocking shoulders 78 opposite the outer end (e.g., at an inward end of the interlocking body). As will be discussed in greater detail below, the pair of interlocking shoulders 78 of each interlocking body is configured to lockingly engage an inwardly facing major surface of a flange blank adjacent an interlocking aperture 42 when the reel assembly 20 is configured in the reel configuration. Likewise, as will be discussed in greater detail below, the interlocking body 74 of each push tab 60 has a major surface 79 that is configured to engage the outwardly facing major surface 32 of a flange blank 24 adjacent a respective one of the interlocking apertures 42 as the push tab is being inserted therein. Each interlocking body 74 has a body width WB (
As mentioned above, fold joints 73 connect the interlocking portion 70 of each spine 62 with each of a respective pair of wings 64. In the illustrated embodiment each of the fold joints 73 are angled outward from an outer end 76 of a respective interlocking body 74 toward a respective one of the pair of interlocking shoulders 78. As will be discussed in greater detail below, the wings 64 of each push tab 60 are configured to bend along the fold joints 73 when the push tab is inserted in an interlocking aperture 42. The angled fold joints 73 provide improved (as compared with non-angled fold joints) relief and ease of use when the push tab 64 is inserted into the interlocking aperture 42. In addition, the angled fold joints 73 improve the ease of disengagement of the push tab 64 from the interlocking aperture 42. When the push tab 64 is pulled through the interlocking aperture 42, the wings 64 also bend away from the coplanar position with respect to the spine 62, and the angled fold lines provide similar relief during disengagement. However, other fold joint orientations may also be used without departing from the scope of the invention.
The interlocking shoulders 78 are formed at respective junctions between an overlay portion 68 of a spine 62 and an interlocking body 74. Each of the illustrated overlay portions 68 narrows as it extends laterally (with respect to the hub portion 50) outward from a respective fold joint 66. Each overlay portion 68 of a spine 62 is narrower near its fold joint 72 (i.e., an interlocking body-adjacent fold joint) than its fold joint 66. In the illustrated embodiment, the overlay portion 68 has approximately the same width as the body width WB of the interlocking body 74 at the fold joint 66. The overlay portion 68 has a considerably shorter width than the body width WB of the interlocking body 74 adjacent the fold joint 72. As a result, the pass through slot 40 of a flange blank 24 is, in preferred embodiments, designed to have a pass through width WPT slightly wider than the body width WB of a respective push tab 60. As will be discussed in greater detail below, in some embodiments, a length of a an overlay portion 68 adjacent the fold joint 66 is received in the pass through slot 40 when a push tab 60 is locked into place with respect to a flange blank 24. Because the width of the overlay portion 68 near the fold joint 66 is approximately the same as the width of the body WB, the pass through width WPS of the illustrated pass through slot 40 is sized to receive the overlay portion adjacent the fold joint 66 and prevent the push tab 60 from moving significantly in a direction parallel to the width of the overlay portion. For example, in some embodiments the pass through width WPS of the pass through slot 40 is about 100% to about 110% of the width of the overlay portion received therein. As discussed above, the length of a pass through slot 40 is, in preferred embodiments, also sized to receive the thickness of the core blank 22. The dimensions of the illustrated pass through slot 40 are, thus, sized to receive a portion of a push tab 60 adjacent its fold line 66 and thereby secure the core blank 22 from movement in two dimensions relative a flange blank 24.
As shown best in
One exemplary commercially available material that conforms to the illustrated embodiment is Plastic IntePro®, which is sold by the assignee of the present application. IntePro® of the illustrated embodiment is made of either PP or PE. Plastic materials such as Plastic IntePro® may be preferred over non-plastic materials to maximize the reusability of the core blank 22. As discussed in greater detail below, a plastic material such as Plastic IntePro® offers advantages in establishing robust fold lines in the core blank 22. Plastic IntePro® is a strong material that can withstand exposure to harsh elements. Though plastic materials are suitable for many applications, it is contemplated that other materials may have properties that serve the needs of other applications. Such other materials may be used without departing from the scope of the invention.
In a preferred embodiment, the longitudinal axes of the plurality of flutes 90 are oriented parallel to the longitudinal axis of the hub portion 50. As discussed above, the hub portion 50 includes a plurality of core joints 56 that extend between the opposite lateral ends 52 of the hub portion and that define fold lines. The core joints 56 are oriented transverse to the longitudinal axes of the plurality of flutes 90 in the core blank 22. In preferred embodiments, the core joints 56 are formed as heat scores in the core blank 22. For example, each of the core joints 56 comprises a line in the core blank 22 along which each of the pair of plastic sheets 92 is sealed (e.g., heat-sealed) against one another. Thus, the hub portion 50 of the core blank 22 comprises, in preferred embodiments, plastic fluted material that has undergone a heat scoring process in which the flutes 90 of the plastic board are heat-sealed in a crosswise direction at spaced intervals (e.g., at core joints 56) by a press roller. The heat scoring process forms spaced indentations in the core blank 22 and air pockets in the flutes 90 extending therebetween. In other embodiments, the core joints are formed by merely scoring the preferred fold lines (e.g. pre-creasing or otherwise crushing the flutes along the fold lines). Still other core joint types, including no pre-trained core joints whatsoever, may be used without departing from the scope of the invention.
One benefit realized with the heat scoring process is it advantageously reduces the flexural strength of the core blank 22 along the core joints 56. In some embodiments, it is desirable to have a very strong core blank 22 to support heavy loads (e.g., heavy lines of elongate flexible material). Fluted plastic material such as IntePro® can provide the necessary strength, particularly when the thickness of the fluted plastic material exceeds three millimeters. However, with the strength to support heavy loads comes increased rigidity that resists bending from a planar configuration (
In addition to the core joints 56, the fold lines 66, 72, and 73 may also be formed using heat scoring in certain embodiments. In other embodiments, the fold lines 66, 72, and 73 may be trained into the material of the core blank 22 using other methods. In still other embodiments, the fold lines 66, 72, and 73 may not be trained into the material of the core blank 22 at all. For example the fold lines 66 and 72 may align with respective flutes 90 of plastic fluted material. In such embodiments, the aligned flutes 90 may naturally tend to collapse along the fold lines 66 and 72 as the push tab 60 is folded toward a desired position.
Referring to
Referring to
In preferred embodiments, each of the push tabs 60 responds at least partially resiliently to the bending along fold lines 73 that occurs when the push tab is being inserted in the respective interlocking aperture 42. Each of the wings 64, in these preferred embodiments, is configured to resiliently return toward its respective coplanar position with respect to its spine 62 when the push tab 60 is received in the interlocking aperture 42. As shown best in
In the illustrated embodiment, the push tab 60 is configured such that, when received in the interlocking aperture 42, the interlocking shoulders 78 engage the inwardly facing major surface 30 of the flange blank 24. As discussed above, the shoulders 78 each have a flat end that engages the inwardly facing major surface 30 of the flange blank 24 across its entire length. The only portion of the of each shoulder 78 that does not engage inwardly facing major surface 30 is the radiused outer corner portion. By comparison, a dart-type lock is angled along flange-adjacent edges (such as shoulders) so that it can be pulled back through its opening during disassembly. This angled engagement surface does not engage a flange along a substantial portion of its length. As a result, the locking capability of dart-type tabs is compromised in comparison with the locking capability of the illustrated push tab 60.
Each of the push tabs 60 is passed through a corresponding pass through slot 40 and inserted in a corresponding interlocking aperture 42 as described above to lockingly engage each of the interlocking structures 26 and secure the reel assembly 20 in the reel configuration of
Once each push tab 60 has been pushed back through its interlocking aperture 42, the flange blanks 24 are removed from the core blank 22. The push tabs 60 are passed back through and out their respective pass through slots 40. If the longitudinal ends of the hub portion 50 of the core blank 22 were secured to one another, they are unsecured. The core blank 22 is manually unfolded toward its planar configuration (
Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
| Number | Name | Date | Kind |
|---|---|---|---|
| 697668 | Schleicher | Apr 1902 | A |
| 2799458 | Nye | Jul 1957 | A |
| 3058775 | Schliephacke | Oct 1962 | A |
| 3869079 | Oglesbee | Mar 1975 | A |
| 3876073 | Herbetko | Apr 1975 | A |
| 4830270 | Holmes | May 1989 | A |
| 5509620 | Crews | Apr 1996 | A |
| 5735483 | Bierlein | Apr 1998 | A |
| 5791590 | Zuk et al. | Aug 1998 | A |
| 6575398 | Nakamura et al. | Jun 2003 | B2 |
| 20070170234 | Cargile, Jr | Jul 2007 | A1 |
| Number | Date | Country |
|---|---|---|
| DE 3703018 | Aug 1987 | AT |
| 2047652 | Jan 1995 | CA |
| 29502721 | Aug 1995 | DE |
| 2165214 | Apr 1986 | GB |
| EP 2565140 | Mar 2013 | IT |
| EP 2634127 | Sep 2013 | IT |
| Number | Date | Country | |
|---|---|---|---|
| 20150307316 A1 | Oct 2015 | US |
