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 facilitates recycling while maintaining sufficient structural integrity for normal use.
In one embodiment, a reel includes a core having a first end region defining a plurality of windows, a first flange configured, in a connected state, to connect to the first end region of the core, and a first collar configured, in the connected state, to affix to the first end region of the core and the first flange. The reel further includes a plurality of first latch members configured, in the connected state, to engage a respective window of the plurality of windows so as to connect the first end region of the core to the first flange.
In another embodiment according to the disclosure, a method of assembling a reel includes moving an end region of a core into an annular channel of a flange; engaging, with each latch member of a plurality of latch members, a respective window of a plurality of windows defined in an end region of a core so as to connect the end region to a flange; and affixing a collar to the end region and the flange.
For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains.
Flexible media, not shown, but which can include cable, wire, fiber optical cable, rope, string, etc., can be wound around the core 18 and axially retained on the core by the flanges 12, 14. As will be discussed in further detail below, each of the collars 20 has features that interact with corresponding features on the respective flange 12, 14 and corresponding features of the core 18 in a locked configuration to securely connect the flanges 12, 14 to the core 18.
The core 18 is formed as a hollow, preferably cylindrical, body 19 having a first end region 19a connected to the first flange 12 and a second end region 19b connected to the second flange 14. Each of the first and second end regions 19a, 19b defines a plurality of windows or windows 26 and a plurality of axial linear notches 28 that are defined entirely through the thickness of the hollow body 19. More specifically, each of the windows 26 extends through the hollow body 19 and is disposed proximate the respective axial end region 19a, 19b of the core 18, but is spaced apart from the end surface. Each of the notches 28 extends axially inwardly from the end surface of the respective end region 19a, 19b of the core 18.
In the illustrated embodiment, the flanges 12, 14 and the collars 20 are substantially identical at each end of the core 18. The following description therefore only describes the connection between the second end region 19b of the core 18, the flange 14, and one of the collars 20, though the reader should appreciate that the flange 12 and collar 20 at the opposite end region 19a of the core 18 may be substantially identical. However, in some embodiments, the flange and collar locking arrangement described herein may be present at only one end of the core 18, and the opposite end may be connected by another desired connection arrangement.
Each of the flanges 12, 14 is shaped generally in the form of a disk that includes various ribs and features as shown, and includes a core nest or channel 72 configured to receive the axial end regions 19a, 19b of the core 18. Each of the flanges 12, 14 has an outer annulus 14a, and a hub wall 14b that is radially surrounded by the outer annulus 14a. In addition, each flange 12, 14 includes a plurality of latch members 40 disposed proximate the core channel 72. More detail regarding the latch members 40 is provided below in connection with
The collar 20 includes an annular wall 30, an annular rim 32, and a plurality of secondary latches 34. The annular wall 30 extends axially from a first end 30a coupled to the annular rim 32 to a second end 30b, and has a greater radial thickness at the first end 30a than at the second end 30b. As a result, the outer radial surface 30c of the annular wall is angled radially inwardly from the first end 30a to the second end 30b. An axial recess 37 is defined in the outer circumferential surface 30c adjacent to each of the secondary latches 34 and in a position in which it interfaces with the associated latch member 40 of the flanges 12, 14. The axial recesses 37 have a generally axially extending wall or, in other words, the wall forming the interior portion of the axial recess 37 is not angled in the manner of the outer circumferential surface 30c.
The plurality of secondary latches 34 are disposed distributed about the annular wall 30, and each secondary latch 34 is formed by a pair of notches 35 defined extending inwardly from the second end 30b of the annular wall 30. Each secondary latch 34 includes a latch arm 36, which is formed by the material of the collar 20 between the respective pair of notches 35, and a latch hook or ledge 38. The latch ledges 38 are approximately aligned with the second end 30b of the wall 30 and include a beveled surface 38a on the radially inner and axially distal end of the latch ledge 38.
When assembled, the core 18 is disposed between and connected to the first flange 12 and the second flange 14 as shown in
In particular, the latch member 40 is disposed in the cavity 52 that is defined in the hub wall 14b. The hub wall 14b is a flat surface in the form of an annulus that extends between a central opening 75 in which an axle may be inserted for rotation of the reel 10, and the core channel 72. As shown in
The block 44 is connected at the distal end 42b of the arm 42 and is formed as an enlarged section that extends axially inwardly (i.e. in the direction toward the axial center of the reel 10, or toward the opposite flange 12) and radially inwardly from the arm 42. The latch portion 48 is disposed on the axially and radially inward edge of the block 44 and forms a rounded or chamfered surface 48a that is rounded or angled in the axially and radially inward directions so as to smooth the inward edge of the latch portion 48.
As shown in
In the aforementioned partially-connected or intermediate state, the latch members 40 are snap-fit into the windows 26 of the core 18, but the latch members 40 can still be deformed radially outwardly such that the latch portions 48 disengage from the windows 26. Thereafter, the collar 20 is aligned with the flange 14 such that the latch ledges 38 of each of the secondary latches 34 on the collar 20 aligns with the arm 42 of a respective one of the latch members 40, as also shown in
As a result, as best seen in
Additionally, in the illustrated embodiment and as best seen in
In a second embodiment, a collar similar to the collar 20 includes latches that are connected directly to the core. In particular,
The core 118 is formed as a hollow, preferably cylindrical, body 119 having a first end region 119a connected to the first flange 112 and a second end region 119b connected to the second flange 114. Each of the first and second end regions 119a, 119b includes a plurality of windows or windows 126 and a plurality of axial linear notches 128 that are defined entirely through the thickness of the hollow body 119. More specifically, each of the windows 126 extends through the hollow body 119 and is disposed proximate the respective axial end region 119a, 119b of the core 118, but is spaced apart from the end surface. Each of the notches 128 extends axially inwardly from the end surface of the respective end region 119a, 119b of the core 118.
In the illustrated embodiment, the flanges 112, 114 and the collars 120 are substantially identical at each end of the core 118. The following description therefore only describes the connection between the second end region 119b of the core 118, the flange 114, and one of the collars 120, though the reader should appreciate that the flange 112 and collar 120 at the opposite end region 119a of the core 118 may be substantially identical. However, in some embodiments, the flange and collar locking arrangement described herein may be present at only one end of the core 118, and the opposite end may be connected by another desired connection arrangement.
Each of the flanges 112, 114 is generally in the form of a disk that includes various ribs and features as shown, and includes a core nest or channel 172 configured to receive the axial end regions 119a, 119b of the core 118. Each of the flanges 112, 114 has an outer annulus 114a, and a hub wall 114b that is radially surrounded by the outer annulus 114a. Like the flanges 12, 14, the core channel 172 is disposed more or less radially between the outer annulus 114a and the hub wall 114b. Each of the flanges 112, 114 includes a plurality of axial openings 140 in the bottom of the core channel 172. More detail regarding the openings 140 is provided below in connection with
The collar 120 includes an annular rim 132 and a plurality of latch members 134 projecting axially inwardly from the annular rim 132. The latch members 134 extend axially from a first, proximal, end 134a coupled to the annular rim 132 to a second, distal, end 134b. Each latch member 134 includes a latch arm 136, which defines at least one recess 137, two of which are depicted in the illustrated embodiment, and a latch hook or ledge 138 that projects radially inwardly from the latch arm 136 at the second end 134b of the latch member 134. The radially outward surface 139 of the latch arm 136 outside the recesses 137 is angled such that the proximal end 134a has a greater radial thickness than the distal end 134b. The latch ledges 138 include a beveled surface 138a on the radially inner and axially distal end of the latch ledge 138.
When assembled, the core 118 is disposed between and connected to the first flange 112 and the second flange 114, similar to the structure of the reel 10 shown in
Additionally, at least one angled rib 162, two of which are depicted in the illustrated embodiment, is formed projecting radially inwardly from the outer circumferential wall 156. The angled ribs 162 are circumferentially aligned with the recesses 135 of the latch arm 134 such that the angled ribs extend into the recesses 135. The angled rib is configured such that the end 162a at the base of the receiving channel 155 extends further in to the receiving channel 155 than the end 162b at the outer axial end of the receiving channel 155 and, in particular, the end 162a of the angled rib 162 at the base of the receiving channel 155 extends across the entire radial thickness of the receiving channel 155.
To construct the reel 110, the core 118 is aligned with the flange 114 such that the windows 126 generally align with the openings 140 in the core channel 172, as illustrated in
Thereafter, the collar 120 is aligned with the flange 114 such that the latch ledges 138 of the latch members 134 on the collar 120 align with the openings 140 in the core channel 172 and, in particular, the recesses 135 are aligned with their associated angled ribs 162. The collar 120 is then inserted into the channel 155 such that the beveled surfaces 138a of the latch ledges 138 engage the outer end surface 119c of the hollow body 119 of the core 118, while at the same time the angled surface of the angled ribs 162 engage with the base of the recesses 135 to urge the latch members 134 radially inwardly. The latch members 134, the angled ribs 162, and the second end region 119b of the hollow body 119 elastically deform to enable the latch ledges 138 to pass into the receiving channel 155 and, when the latch ledges 138 are aligned with the windows 126, the latch ledges 138 snap into the windows 126 of the core 118.
Once the latch ledges 138 are received in the windows 126, the interaction between the latch ledges 138 and the windows 126 disables axial movement of the collar 120 relative to the core 118. Further, the angled ribs 162 disable the latch ledges 138 from moving radially out of the channels 126 and, in some embodiments, apply a reinforcing force that further aids in retaining the latch ledges 126 in the channels 126. Because the circumferential rim 159 is interposed between the end surface 119c of the hollow body 119 of the core 118 and the annular rim 132 of the collar 120, and the collar 120 and core 118 are disabled from axial movement relative to one another, the flange 114 is also fixed in position relative to both the core 118 and the collar 120. As a result, the flange 114, core 118, and collar 120 are all fixedly connected to one another. As noted above, the opposite flange 112 may be connected to the core 118 and the opposite collar 120 in the same manner.
The disclosed connections between the flanges 12, 14, 112, 114, the core 18, 118, and the collars 20, 120 provide a simple yet strong connection to retain the flanges 12, 14, 112, 114 to the core 18, 118. In addition, the components forming the connections can all be molded of plastic in either a single-shot or a double-shot injection molding process, enabling cost-effective manufacture of the disclosed reels 10, 110.
Additionally, since assembly of the reels 10, 110 is user-friendly, the reels 10, 110 can be shipped in a disassembled state as a kit with the flanges 12, 14, 112, 114 stacked upon one another and one or more cores 18, 118 and the collars 20, 120 packed in a compact state. As a result, shipping costs of delivering the reels 10, 110 can be reduced, while still enabling the end-user to easily assemble the reels 10, 110.
In particular, the engaging of the latch members 40 may occur concurrently with inserting the core 18 by, for example, engaging the latch members 40 of the flange 12, 14 in the windows 26 as in the embodiment described above with reference to
It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the foregoing disclosure.
This application claims priority to U.S. Provisional Application Ser. No. 63/506,293 entitled “Snap-Together Reel with Reinforcing Collar” filed Jun. 5, 2023, the disclosure of which is incorporated herein by reference in its entirety.
Number | Date | Country | |
---|---|---|---|
63506293 | Jun 2023 | US |