Reel Made from Separable Components

Abstract

The disclosure concerns large reels used for transportation and storage of cables or wires. The present invention describes a separable cable reel which is constructed from component parts which may be quickly and easily disassembled and reassembled. The separable reel design has four primary components: a first flange, a second flange, a core, and a plurality of looped bands. The two flanges are coupled to the core and the band or bands are coupled between the two flanges.

Description

BACKGROUND

Field of the Invention

This invention relates to large reels; more particularly, this invention relates to large reels used for transportation and storage of cables, wires, hoses or other similarly shaped objects.

Description of the Related Art

Large reels, also referred to as spools or spindles, are used for storing and transporting utility cables and heavy gauge wires. These reels may come in a variety of sizes, typically having a flange diameter of between 2-feet to 8-feet. A fully loaded reel can be very heavy, requiring heavy equipment for transportation. Conventional reels are constructed with permanent and semi-permanent means. These permanent and semi-permanent reel construction designs do not provide the user with a quick and simple way to disassemble and reassemble the reel.

Because there is no quick and simple way to disassemble and reassemble a conventional reel, the empty conventional reels are commonly shipped fully assembled. This limits the number of empty conventional reels that may be shipped at a time using a given cargo area such as a semi-truck trailer. Because conventional reels cannot be easily disassembled additional semi-trucks are required to transport additional reels. If large reels were constructed such that they could be more easily disassembled into their component parts, more disassembled reels would be able to fit in a given cargo area when compared to assembled reels. This would result in fewer truck trips to transport the empty disassembled reels.

SUMMARY

The disclosure concerns large reels used for transportation and storage of cables or wires. The present invention describes a cable reel which is constructed from component parts which may be readily disassembled and reassembled. This reel design is referred to as the “separable reel” or simply “the reel” herein. The separable reel design has four primary components. In some embodiments, these primary components may be assembled from subcomponents. The four reel components are a first flange, a second flange, a core, and one or more looped bands, the looped bands. The looped bands are also referred to simply as “bands” herein.

The separable reel has two flanges and a cylindrical core which is coupled to, and spans between, the two flanges. The distance between the inner sides of the flanges is referred to as the inside traverse. The distance between the outer side of the first flange and the outer side of the second flange is referred to as the overall width.

The cable to be stored or transported is wrapped around the core, and the flanges prevent the cable from falling off the ends of the core. The separable reel may utilize features which make it easier to transport and use. In preferred embodiments, the flanges are circular such that the cable reel may be rolled on its flanges. The separable cable reel may have a central penetration which passes through the central axis of both flanges and the core. This central penetration is called the arbor hole.

The load-bearing structure of the core is made from a number of struts which span between the two flanges. In preferred embodiments, these struts are arranged in a generally circular pattern about the central axis of the reel.

The struts are held in place in-part by inserting the ends of the struts into recesses located on the inner side of each flange. These recesses are called strut pockets, and they may be arranged in a circular pattern so that as each strut is inserted into opposing strut pockets, the struts form a cylindrical core structure.

The reel is held together by bands. The bands are coupled between the two flanges, and they pull the flanges together. The bands may be made with steel. A steel band may be connected back to itself using steel band clips. When placed in tension between the flanges, the bands pull the two flanges towards each other which imparts a compressive force on the core. The compressive force holds the strut ends in the strut pockets.

In some embodiments of the separable reel, core panels are installed on the outside of the core struts such that when a cable is wrapped around the reel the cable rests on the core panels. Similar to the struts and strut pockets, the inner side of the flanges may be configured with panel pockets. The ends of the panels may be inserted into the panel pockets to hold the panels in place.

Typically, when the cable reel is configured to pay out cable at a construction site, a rod is inserted through the arbor hole such that by lifting up on one or both of the ends of the rod the cable reel may be suspended above the surface below. When the reel is suspended by the rod it may be rotated about its central axis. This rotation allows the cable to be pulled off of the reel and installed where needed.

After the cable has been completely paid out, the spool will be empty. The crew responsible for transporting the separable reel may now disassemble the reel and load it onto a transportation vehicle. In order to disassemble the reel the crew will remove the bands. Two ways the bands may be removed is by removing the band clips or by cutting the bands off of the reel. When the bands are removed the flanges may be pulled away from the core. By doing so the struts may be removed from the strut pockets and strut slots, and the core panels may be removed from the panel pockets. The core fixtures may or may not be separated from the flanges during disassembly.

Each of the component parts of the separable reel may then be loaded onto a truck and transported. The component parts of a separable reel have a denser packing factor than an assembled reel, allowing more separable reels to be transported using fewer truck loads. When desired, the component parts may be reassembled into a reel. New bands and band clips may be used when reassembling a reel. In preferred embodiments, the component parts of the reel are designed to be interchangeable with other component parts of similar reels.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, combinations, and embodiments will be appreciated by one having the ordinary level of skill in the art of large reel manufacturing upon a thorough review of the following details and descriptions, particularly when reviewed in conjunction with the drawings, wherein:

FIG. 1 shows a isometric view of the reel in accordance with a first illustrated embodiment;

FIG. 2 shows an exploded front view of the reel in accordance with a first illustrated embodiment;

FIG. 3 shows a perspective view of the core in accordance with a first illustrated embodiment;

FIG. 4 shows an exploded perspective view of the core in accordance with a first illustrated embodiment;

FIG. 5 shows a side view of a core fixture in accordance with a first illustrated embodiment;

FIG. 6 shows a side view of a flange inner side in accordance with a first illustrated embodiment;

FIG. 7 shows an exploded view of the flanges, core fixtures, and bands in accordance with a first illustrated embodiment;

FIG. 8 shows a perspective view of the flanges, core fixtures, and bands in accordance with a first illustrated embodiment;

FIG. 9 shows a magnified view of a band hole in accordance with a first illustrated embodiment;

FIG. 10 shows a magnified view of a band hole in accordance with a first illustrated embodiment;

FIG. 11 shows a magnified view of a band hole in accordance with a first illustrated embodiment;

FIG. 12 shows a side view of a flange outer side without covers in accordance with a first illustrated embodiment;

FIG. 13 shows a side view of a flange outer side with covers in accordance with a first illustrated embodiment;

FIG. 14 shows the back view of the reel in accordance with a first illustrated embodiment;

DETAILED DESCRIPTION

For purposes of explanation and not limitation, details and descriptions of certain preferred embodiments are hereinafter provided such that one having ordinary skill in the art may be enabled to make and use the invention. These details and descriptions are representative only of certain preferred embodiments, however, a myriad of other embodiments which will not be expressly described will be readily understood by one having skill in the art upon a thorough review of the instant disclosure. Accordingly, any reviewer of the instant disclosure should interpret the scope of the invention only by the claims, as such scope is not intended to be limited by the embodiments described and illustrated herein.

Unless explicitly defined herein, terms are to be construed in accordance with the plain and ordinary meaning as would be appreciated by one having skill in the art.

General Description of Embodiments

A large reel made from separable components is disclosed. In some embodiments, the reel has a first flange, a second flange, a core which is coupled to both the flanges, one or more looped bands which are coupled to the first and second flanges in order to pull the flanges towards each other.

In some embodiments, the pair of flanges on a given reel are duplicates of each other, having the same design, dimensions, features, and being made from the same materials. The flange is shaped as a generally flat panel with an outer side, an inner side, a central penetration, and a plurality of strut pockets. In some embodiments, the flange is circularly shaped.

In some embodiments, the central axis of the first flange and the central axis of the second flange are aligned, making the plane extending radially outward from the central axis of the first flange parallel to the plane extending radially outward from the central axis of the second flange.

In preferred embodiments, the flanges have strut pockets located on the inner side of each flange. The strut pockets may be shaped and located such that they can receive the ends of the core struts. The strut pockets may be arranged around the central axis of the flange.

In some embodiments, the flanges may be constructed by attaching multiple flange shaped panels together “face-to-face.” This construction method may help with the strength, rigidity, and durability of the flange. In addition, some of the inner flange sub-panels may have different pockets, penetrations, or other features compared to the outer sub-panels. For example, in some embodiments an inner sub-panel may be configured with holes, and an outer sub-panel may lack those holes. When assembled, the inner face of an outer sub-panel may form the bottom surface of the strut pocket, and the hole through the inner sub-panel may form the strut pocket sidewall.

There is not an definite upper limit on the size (diameter) of the flanges, or the reel more generally.

In some embodiments, the core of the reel is generally cylindrically shaped. When assembled, the central longitudinal axis of the core may be coaxially aligned with the flanges. The load bearing structure of the core is made up of a plurality of struts. Each individual strut has a first end and a second end. In some embodiments, the struts are wood boards, for example without limitation “2-inch by 4-inch” boards. The first end of a given strut may be inserted into a strut pocket on the inner face of the first flange. The second end of a given strut may be inserted into a strut pocket on the inner face of the second flange. The strut pocket constrains the movement of the inserted strut. In some embodiments, the strut pockets are rectangularly shaped. Furthermore, strut pockets may be arranged such that the major axis of their rectangular shape is aligned with a radius emanating from central axis of the flange.

In preferred embodiments, the reel is held together by a plurality of bands. In some embodiments, the bands may be made out of a metallic material such as steel. The bands may have a first end and a second end. In some embodiments, the bands are looped and attached back to themselves. The first end of the band, also referred to as the first looped end, may be attached or coupled to the first flange. The second end of the band, also referred to as the second looped end, may be attached or coupled to the second flange.

As the bands are installed on the assembled separable reel the installer applies tension to the bands which pulls the two flanges towards each other. As the flanges are pulled together they apply a compressive force to the core struts. The compressive force pushes the core struts into the strut pockets, securely seating the core struts within the strut pockets.

In some embodiments, the flanges may have penetrations called band holes. In preferred embodiments, the bands are looped through two band holes on the first flange and two band holes on the second flange. The bands may be looped in the following way: beginning from the outer side of the first flange, a band may pass through a band hole towards the interior of the reel, pass through a band hole on the second flange towards the outer side of the second flange, traverse a distance along of the outer side of the second flange before passing through a separate band hole in the second flange towards the interior of the reel, pass through a fourth band hole on the first flange and be attached to itself. The point at which the band is attached to itself may be located at any point along the loop. The preferred embodiment has looped bands which are attached to themselves, however the bands may be attached and held in place in a variety of ways so long as the band is installed between the two flanges and placed under tension.

In some embodiments, core panels are configured around the core struts. These core panels may provide the reel core with a surface onto which the wrapped cable may make additional contact when compared to a core which lacks core panels. The core panels may be supported by the struts below the core panels. In some embodiments, there are three core panels disposed around the core struts.

In preferred embodiments, the flanges may have panel pockets on the inside of the first and second flanges. The panel pockets may be shaped such that they can receive the ends of the core panels. The panel pockets may be arranged around the central axis of the flange, outside of the strut pockets. The core panels may be curved to wrap around the struts. As the reel is assembled the core panels may be inserted into the panel pockets. The panel pockets may constrain the horizontal and vertical movement of the inserted panels.

In preferred embodiments, a core fixture may be utilized to strengthen the coupling between the flanges and the core struts. In some embodiments, the core fixture is a generally flat panel with an outer side, an inner side, a central penetration, and a plurality of strut slots or strut holes. The outer side of a core fixture may be attached or coupled to the inner side of the first and second flanges. The strut slots in the core fixture may align with the strut pockets. The central penetration of the core fixture may align with the central penetration of the flange it is mounted to. The strut slots may provide additional supporting surface area for the inserted strut ends, thereby increasing the strength of the coupling between the flanges and the core.

In some embodiments, the core fixture may have band slots or band holes. Similar to the strut slots, the band slots may provide additional supporting surface area to directly or indirectly receive the forces applied to the bands. Use of core fixtures with strut slots and band slots may improve the longevity of the separable reel. The core fixtures may be permanently affixed to the flanges or they may be designed to be separated and reattached to the flanges.

In some embodiments, the reel may have covers configured on the outer side of the first or second flange to cover and protect components, such as the looped bands, or features, such as the RFID feature, the accelerometer feature, the GPS feature, etc. The covers may be generally low profile components such that they do not protrude from the surface of the outer side of the flange.

In some embodiments, the outer side of the flange may have one or more shallow pockets where the cover is to be installed such that when the cover is installed the cover protrudes outward from the outer surface of the flange less than if there were no pocket or pockets. The cover may be in a single piece or it may be made from multiple sub-covers. The covers may also have writing, logos, insignia, or the like.

In some embodiments, the separable reel may be configured with a RFID feature. In some embodiments, the RFID feature is a RFID unit capable of being assigned a RFID tag to identify a given reel. In some embodiments, the RFID feature is a location on the reel where the user may install a RFID unit of their choosing. In some embodiments, the outer side of the flange may be configured with a pocket for the RFID feature to be disposed within. In some embodiments, the RFID pocket may be located below a cover such that the cover protects the RFID from damage.

In some embodiments, the separable reel may be configured with an accelerometer feature. In some embodiments, the accelerometer feature is an accelerometer unit which may be capable of tracking and recording the accelerations the reel is subjected to. In some embodiments, the accelerometer feature is a location on the reel where the user may install an accelerometer of their choosing. In some embodiments, the outer side of the flange may be configured with a pocket for the accelerometer feature to be disposed within. In some embodiments, the accelerometer pocket may be located below a cover such that the cover protects the accelerometer from damage.

In some embodiments, the separable reel may be configured with a Global Positioning System (GPS) feature. In some embodiments, the GPS feature is an GPS tracking unit which may be capable of tracking, recording, or transmitting the location of the reel it is applied to. In some embodiments the GPS feature is a location on the reel where the user may install a GPS tracking unit of their choosing. In some embodiments, the outer side of the flange may be configured with a pocket for the GPS feature to be disposed within. In some embodiments, the GPS pocket may be located below a cover such that the cover protects the GPS from damage.

Manufacturing

For example and without limitation, the struts and bands used in some embodiments can be obtained commercially. Alternatively, the struts and bands can be customized in accordance with the level and knowledge of one having skill in the art

Generally, the flange, core struts, core panels may be made of wood or wood products. Otherwise, the flange, core struts, and core panels can be fabricated in accordance with the level and knowledge of one having skill in the art.

Generally, the bands may be made of steel. Otherwise, the bands can be fabricated in accordance with the level and knowledge of one having skill in the art.

Each of the components of the separable reel and related system described herein may be manufactured and/or assembled in accordance with the conventional knowledge and level of a person having skill in the art.

While various details, features, combinations are described in the illustrated embodiments, one having skill in the art will appreciate a myriad of possible alternative combinations and arrangements of the features disclosed herein. As such, the descriptions are intended to be enabling only, and non-limiting. Instead, the spirit and scope of the invention is set forth in the appended claims.

First Illustrated Embodiment

The first illustrated embodiment of the separable reel (100) is shown in the drawings. FIG. 1 shows the assembled reel having a first flange (301), a second flange (302), a core (200) which spans between the first and second flanges, and a plurality of looped bands (400). FIG. 1 also shows covers (311) disposed over the bands where the bands transit the outer side of the second flange.

In FIG. 2 the reel is shown in a disassembled or “exploded” view such that the components of the reel may be seen separately. FIG. 2 shows that the core may have a plurality of struts (201) which span between the first and second flanges. The core struts may be covered with a plurality of core panels. The first core panel (208), second core panel (209), and third core panel (210) are shown in FIG. 2. The reel flanges may be pulled towards each other around the core with a plurality of looped bands (400). The first band (401), second band (402), and third band (403) are shown in FIG. 2. A first core fixture (204) and a second core fixture (205) are also shown in FIG. 2. These core fixtures may be mounted to the inner sides of the flanges to provide additional support for the struts.

FIG. 3 shows an assembled core. FIG.4 shows the same core (200) but in a disassembled, exploded view. The plurality of struts (201) have a strut first end (202) and a strut second end (203). The strut first ends are inserted into the first core fixture (204), and the strut second ends are inserted into the second core fixture (205). FIG. 4 also shows that each of the core panels have a panel first end (211) and a panel second end (212). The panel first and second ends are oriented around the strut first and second ends respectively.

FIG. 5 shows a side view of a core fixture (204, 205). The core fixture is configured with strut slots (206) which cradle the inserted struts. The core fixture is also configured with band slots (207) which may support and guide installed bands. In the first illustrated embodiment, the core fixture is made from three core fixture sub-parts (214).

FIG. 6 shows an inner side view of a flange (300). A plurality of strut pockets (308) are configured on the flange inner side (304) such that struts (201) may be inserted into the strut pockets. A plurality of panel pockets (309) are also configured on the inner side of the flange such that panels may be inserted into the panel pockets. FIG.6 shows the band holes (310) which penetrate the flange and allow the bands to pass through the flange. The flange edge (305) and the central arbor hole (306) are also identified in FIG. 6.

FIG. 7 shows an exploded view of the first flange (301), second flange (302), first core fixture (204), second core fixture (205), and the looped bands (400). The flange outer side of the second flange is shown with band holes (310). Each band may have a band first end (404) and a band second end (405). Each band first end may be coupled to the first flange (301), and each band second end may be coupled to the second flange (302).

FIG. 8 shows an assembled view of the first flange (301), second flange (302), first core fixture (204), second core fixture (205), and the looped bands (400). The core struts and core panels are not shown in FIG. 8. The band clips (406) which may couple one band to itself are shown in FIG. 8. The strut slots (206) of the first core fixture (204) are aligned with the strut pockets (308) of the first flange (301).

FIG. 9, FIG. 10, and FIG. 11 show magnified views of the band holes (310). The first band (401), second band (402), and third band (403) are shown passing through the band holes (301). FIG. 12 shows the outer side (303) of a flange (300). Disposed on the flange outer side are an RFID feature (501), a GPS feature (502), and an accelerometer feature (503). The arbor hole (306) through the flange is also shown. FIG. 13 shows the same flange outer side with the covers (311) installed.

FIG. 14 shows a back side view of the reel. Each flange (300) may be made from multiple flange sub-panels (307) which are coupled or attached together to form a single flange. The starter hole (213) is also shown in FIG. 14.

FEATURE LIST

Reel (100)

Core (200)

Core Struts (201)

Strut First End (202)

Strut Second End (203)

First Core Fixture (204)

Second Core Fixture (205)

Strut Slots (206)

Band Slots (207)

First Core Panel (208)

Second Core Panel (209)

Third Core Panel (210)

Panel First End (211)

Panel Second End (212)

Starter Hole (213)

Core Fixture Sub-part (214)

Flange (300)

First Flange (301)

Second Flange (302)

Flange Outer Side (303)

Flange Inner Side (304)

Flange Edge (305)

Arbor Hole (306)

Flange Sub-Panel (307)

Strut Pocket (308)

Panel Pockets (309)

Band Hole (310)

Covers (311)

Looped Band (400)

First Band (401)

Second Band (402)

Third Band (403)

Band First End (404)

Band Second End (405)

Band Clip (406)

RFID Feature (501)

GPS Feature (502)

Accelerometer Feature (503)

Hardware Penetrations (601)

Hardware (602)

Claims

1. A reel comprising: a. A first flange, the first flange being a generally flat panel having an outer side, an inner side, a central axis, a plurality of strut pockets, and a plurality of band holes; the central axis being an imaginary line passing through the center of the flange between the outer side and the inner side, the strut pockets being recesses arranged around the central axis on the inner side of the first flange; the band holes being penetrations through the first flange between the outer side and the inner side;b. A second flange, the second flange being a generally flat panel having an outer side, an inner side, a central axis, a plurality of strut pockets, and a plurality of band holes; the central axis being an imaginary line passing through the center of the flange between the outer side and the inner side, the strut pockets being recesses arranged around the central axis on the inner side of the second flange; the band holes being penetrations through the first flange between the outer side and the inner side;c. A core, the core having a first, second end, and a central longitudinal axis passing between the first end and second end; the core first end being coupled to the inner side of the first flange and the second end being coupled to the inner side of the second flange; the core comprising a plurality of struts, each strut having a first end and second end, the struts spanning between the first flange and second flange and arranged such that the first ends of the struts are removably inserted into the first flange strut pockets, the second ends of the struts are removably inserted into the second flange strut pockets;d. A plurality of looped bands, each of the looped bands having a first end and a second end; the first end of the looped bands being coupled to the first flange and the second end of the looped bands being coupled to the second flange such that when the looped bands are placed under tension the looped bands pull the first flange and second flange towards each other, applying a longitudinally compressive force to the core struts, seating the struts into the strut pockets.

2. The reel of claim 1, wherein: a. The first flange and second flange are generally circularly shaped such that the center of the circular first flange is coaxial with the central axis of the first flange and the center of the circular second flange is coaxial with the central axis of the second flange.

3. The reel of claim 1, wherein: b. The struts, when assembled in the reel, form a generally cylindrical shaped core which is coaxially aligned with the central axis of the first flange and the central axis of the second flange.

4. The reel of claim 1, wherein: c. The first flange and second flange are made of a plurality of generally flat sub-panels, each sub-panel having an inner side and an outer side, the sub-panels of one flange being attached together face-to-face, with the inner side of an outer sub-panel being attached to the outer side of an inner sub-panel such that additional sub-panels build up the final thickness of the flange

5. The reel of claim 1, wherein: d. The reel has three looped bands.

6. The reel of claim 1, further comprising: e. A plurality of core panels and a plurality of panel pockets; the panel pockets being recesses located on the inner side of the first flange and on the inner side of the second flange, the panel pockets being arranged around the strut pockets in a generally circular pattern, the core panels being curved surfaces having a first end and second end, the panels oriented such that their surface partly or wholly covers the struts, the panels arranged such that the first end of a given panel is removably inserted into one of the first flange panel pockets and the second end of a given panel is removably inserted into one of the second flange panel pockets, the panels forming a generally rounded outer surface around the core struts providing a substantially smooth surface onto which cables may be wrapped.

7. The reel of claim 1, further comprising: f. A first core fixture and a second core fixture, the first and second core fixtures being generally flat panels each having an outer side, an inner side, a central axis, and a plurality of strut slots; the outer side of the first core fixture being coaxially coupled to the inner side of the first flange such that the strut slots align with the strut recesses, the outer side of the second core fixture being coaxially coupled to the inner side of the second flange such that the strut slots align with the strut recesses.

8. The reel of claim 1, further comprising: g. A RFID feature, the RFID feature being disposed on the reel.

9. The reel of claim 1, further comprising: h. An accelerometer feature, the accelerometer feature being disposed on the reel.

10. The reel of claim 1, further comprising: i. A GPS feature, the GPS feature being disposed on the reel.

11. The reel of claim 1, wherein j. The flanges are largely made from wood or wood products.

12. The reel of claim 1, wherein k. The struts are largely made from wood or wood products.

13. The reel of claim 1, wherein l. The core panels are largely made from wood or wood products.

14. The reel of claim 1, wherein m. The looped bands are steel banding straps.

15. The reel of claim 1, further comprising: n. A plurality of covers, the covers being panels which are removably coupled to the outer side of the first flange and/or to the outer side of the second flange, the covers configured over components located on the outer side of the first or second flanges such that those components are protected by the covers.

16. The reel of claim 4, wherein: o. The sub-panels disposed towards the outer side of the first or second flanges are configured without strut pockets such that, when the sub-panels are assembled in the reel, the first and second ends of the struts push outwards against the inner side of the outer sub-panel or sub-panels.

17. The reel of claim 15, wherein: p. The cover or covers are configured over the section or sections of the looped bands which transit the outer side of the first flange and the section or sections of the looped bands which transit the outer side second flange such that the cover or covers protect the looped bands.

18. The reel of claim 15, wherein: q. The RFID feature is located on the outer side of the first flange or second flange behind a cover which covers and protects the RFID feature.

19. The reel of claim 15, wherein: r. The accelerometer feature is located behind a cover which covers and protects the accelerometer feature.

20. The reel of claim 15, wherein: s. The GPS tracking feature is located behind a cover which covers and protects the GPS tracking feature.