Field of the Invention The present invention relates generally to reels for supporting or storing flexible media.

Background of the Invention Reels for storing flexible media, such as wire, hose, fabric, chain link, or rope, typically comprise a core interposed between two flanges. In general, the flexible media is wound or wrapped around the core and held in place by the flanges. Reels that are intended for industrial transport, storage and use of flexible media vary greatly in size. Reels have traditionally been fabricated out of wood or metallic material, and have more recently been fabricated from paper and plastic products.

Reels are commonly produced by assembling individually manufactured flanges and cores. A separate hub may be used to secure each flange to the core, or the hub may be an integral part of the flange. In many designs, paper or plastic flanges are secured to paper or plastic cores using adhesives. In other designs, staples are used. Both designs facilitate relatively simple assembly, and can provide good structural strength.

One drawback to such designs is that the resulting reels are less convenient to break down. In particular, it is often desirable to disassemble or break down a reel after usage in order to ship or store the reel. As a result of environmental conservation efforts, wire and cable consumers are encouraged to return empty reels, or at least the plastic, metal or wood portions thereof, for re-use. However, empty reels can be bulky and inconvenient to ship. As a consequence, it is desirable to disassemble empty reels to facilitate shipping and reduce costs.

For example, a factory might in the general course of business receive reels loaded with wire. As the wire is used, the factory accumulates empty reels. Periodically, the factory returns the empty reels to the wire supplier. In cases where a reel has some paper components and some plastic components, the factory may only return the plastic pieces and dispose of the paper components through general recycling procedures. To accomplish either of the foregoing, the factory preferably disassembles so that they take up less space.

Reels that employ adhesives are somewhat difficult to disassemble because they can require the application of solvents or the like to loosen the adhesive bond. Reels that employ stapling are easier to disassemble, although removal of several deeply implanted staples can be physically challenging.

In another common reel design, bolt and nut type fasteners join the components. While this arrangement is simple and effective, it has some limitations. In particular, the additional parts and labor involved in the use of nuts and bolts can negatively impact the cost effectiveness of the reel.

Accordingly, there is a need for a reel that combines structural strength with convenience and economy of manufacture, and further facilitates disassembly. A reel that facilitates disassembly encourages environment-friendly behavior on the part of industry and/or other consumers of wound flexible media.

Summary of the Invention The present invention fulfills the above stated needs, as well as others, by providing a reel that includes a sleeve on a hub that engages a surface of the core. The sleeve includes the core engagement surface and a recessed surface. The recessed surface receives radial force which, in turn, causes plastic deformation in at least a portion of the sleeve, thereby separating that portion of the sleeve from the surface of the core. Regardless of whether the sleeve is held in place by adhesives, friction, or an interference fit, separating the sleeve from the inner surface of the core facilitates the removal of the sleeve.

Thus, for example, if the sleeve is friction fit around the inside or outside surface of the core, the recessed surface provides a place in which a prying instrument may be placed to effective pry a portion of the sleeve away from the core to release the friction fit. When the friction fit is released, the hub can pull away more easily. In another example, the hub includes interference fit features that hold the hub onto the core. In such example, the recessed portion again provides access by a prying instrument. However, in the interference fit example, the radial prying movement and the resulting movement of the sleeve moves the interference fit feature out of the position in which the positive interference exists. As a result, removal of the hub is facilitated.

The above features and advantages, as well as others, will become readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings.

Brief Description of the Drawings Fig. 1 illustrates an elevational perspective view of an exemplary reel in accordance with the present invention; Fig. 2 illustrates an exploded perspective view of the reel of Fig. 1; Fig. 3 illustrates a cross-sectional view of the reel of Fig. 1; Fig. 4 illustrates a top plan view of an exemplary flange for use in the reel of Fig. 1; Fig. 5 illustrates a first perspective view of an exemplary hub for use in the reel of Fig. 1; Fig. 6 illustrates a second perspective view of the exemplary hub of Fig. 5; Fig. 7 illustrates a top plan view of the exemplary hub of Fig. 5; Fig. 8 illustrates an exploded perspective view of an implementation of the reel of Fig. 1 in a frame that permits relative rotation with respect to the frame; Fig. 9 illustrates a cross-sectional view of another embodiment of a reel according to the present invention; Fig. 10 illustrates a perspective view of a flange for use in the reel of Fig. 9; and Fig. 11 illustrates a top plan view of the flange of Fig. 10.

Detailed Description Figs. 1 and 2 illustrate an elevational perspective views of an exemplary first embodiment of a reel in accordance with the present invention. Fig. 3 shows in further detail a cross-sectional view of the reel 110.

The reel 110 comprises a core 112, first and second flanges 122 and 126, respectively, and first and second hubs 130 and 132, respectively. As will be described in further detail below, the first and second flanges 122 and 126, respectively, each include a plurality of flexible fingers 124,128, respectively.

The core 112 has a first end 114 and a second end 116 axially separated by the body of the core 112. The core 112 includes an inner surface 118 and an outer surface 120. In the first embodiment, the core 112 is preferably a hollow cylindrical structure constructed of rigid pressed paper material. While the use of a cylindrical structure has certain advantages, such as simplicity of manufacture, the core 112 may alternatively have a non-cylindrical structure, such as a hollow or partially hollow structure having a polygonal or elliptical cross section.

The first flange 122 and the first hub 130 are secured to a first end 114 of the core 112.

The second flange 126 and the second hub 132 are secured to a second end 116 of the core 112.

The hubs 130 and 132 support the flanges 122,126 and further help retain the flanges 122,126 on the core 112 by trapping flexible fingers 124,128 on the flanges 122,126 against the inner surface of the core 118.

The hubs 130 and 132 in this embodiment also facilitate rotation of the reel 110 because they are constructed of plastic, unlike the flanges 122,126, which are constructed of paper. The plastic construction of the hubs 130 and 132 provide a smoother and more robust rotating surface than one of paper construction. It is noted that other embodiments where rotation is not necessary, the hubs similar to the hubs 130 and 132 maybe employed solely for support of and/or securing the flanges 122,126 on the core 112. In still other embodiments, hubs may be used solely to assist in rotation.

In any event, in the exemplary embodiment described herein, the first flange 122 attaches to the core 112 via the first plurality of flexible fingers 124. Reference is additionally made to Fig. 4, which illustrates a top view of the first flange 122 apart from the reel 110. The first flange 122 comprises a plate-like annulus having an outer perimeter 135 and a center hole 136.

Although the general circular or annular shape of the first flange 122 is preferred, other shapes may readily be used, such as elliptical or polygonal shapes. The first flange 122 comprises an inner plate 134 and an outer plate 137. (See Fig. 3). The inner plate 134 includes an inner radial edge 138 that defines the center hole 136 and engages the outer surface 120 of the core 112 (See Figs. 3 and 4). The outer plate 137 includes a fold annulus 142 which defines a ring that is in registration with the inner surface 118 of the core 112 (See Figs. 3 and 4).

As shown in Fig. 4, prior to assembly, the first plurality of flexible fingers 124 extends radially inward from the fold radius 142. The first plurality of flexible fingers 124 are typically integrally formed with at least a portion of the annulus of the first flange 122 and in this case, the outer plate 137. In a preferred embodiment, the first flange 122 is constructed of corrugated paper and the first plurality of flexible fingers 124 are formed by die cutting a series of annularly spaced, radial cuts extending inward from the fold radius 142 of the outer plate 137. Once the reel 110 is assembled, the first plurality of flexible fingers 124 extend axially inward the core 112, approximately perpendicular to the radial plane of the annulus of first flange 122 (see Figs.

2 and 3).

The second flange 126 preferably has substantially the same structure as the first flange 122, and the second plurality of flexible fingers 128 are formed in the same manner as the first plurality of flexible fingers 124.

Referring to Figs. 5,6, and 7, the first hub 130 includes a disk-shaped, radially sloped reinforcement portion 150. The reinforcement portion 150 extends radially adjacent the first flange 122 to provide structural support thereto (see Fig. 3). The first hub 130 further includes a substantially cylindrical dynamic bearing 144 that extends axially from and defines an inner radius of reinforcement portion 150. The dynamic bearing 144 terminates in an inner axial edge 145. The first hub 130 is preferably constructed of a plastic material. The use of plastic material for the first hub 130 provides for improved reel rotation and still permits the reel 110 to otherwise be constructed predominantly of paper, as discussed above.

The first hub 130 further includes a substantially cylindrical sleeve 142 disposed radially outward the dynamic bearing 144 and which extends axially from the reinforcement portion 150.

The sleeve 142 includes core engaging surfaces 143, recessed surfaces 172, and barb members 146. The core engaging surfaces 143 are configured to engage the inner surface of the core 118. In the embodiment described herein, the core engaging surfaces 143 form as a group a cylinder that has a radius substantially defined by the inner surface 118 of the core 112.

However, it will be noted that one or only a few core engaging surfaces may be used, so long as they still retain the sleeve 142 within the core 112.

The recessed surfaces 172 define corresponding axial slots 170 in the cylinder otherwise formed by the core engaging surfaces 143. The axial slots 170 co-extend to the axial edge of the core engaging surfaces 143, and may, but need not extend to the barb members 146. The axial slots 170 an external access point through which a screwdriver or other prying mechanism may be disposed between the sleeve 142 and the first plurality of flexible fingers 124 located inside the core 112.

Each of the plurality of barb members 146 engage the axially innermost edge of at least one of the first plurality of flexible fingers 124 of the first flange 122. (See Fig. 3). In a preferred embodiment, each of the plurality of barb members 146 is a wedge-shaped member having radially outward side defining a radial protrusion.

The plurality of barb members 146 secure the hub 130 to the core 112 and/or first flange 122. The flexible fingers 124 are typically secured to the inner surface 118 with an adhesive.

The barb members 146 engagement with the flexible fingers 124 within the core 112 inhibit axial motion of the alternative hub 130 with respect to the first flange 122.

To facilitate disassembly, the barb members 146 are configured to plastically deform inward in response to radially inward pressure on the recessed surfaces 172. To this end, the recessed surfaces 172 are integrally formed with the barb members 142 and the core engaging surface 143 so that radially inward movement of the recessed surfaces 172 translates to radially inward movement of at least a portion of the sleeve that includes the barb members 146. The recessed surfaces 172 are disposed throughout the sleeve 142, preferably, but not necessarily, aligned circumferentially with the barb members 146. As will be discussed below, a prying mechanism may be inserted into the slot 170 and pressed against the recessed surface 172, causing at least one barb member 146 to clear the end of the flexible fingers 124.

Before providing further detail on the disassembly features of the reel 110, the assembly of the reel 110 will be discussed.

During assembly, the first flange 122 is located adjacent to the first end 114 of the core 112 such that the radial edge 138 fits over the outer surface 120 of the core 112. The first plurality of flexible fingers 124 are then forced axially inward the first end 114 of the core 112.

In a preferred assembly method, the first hub 130 is used to force the first plurality of flexible fingers 124 into the core 112. In other words, after the first flange 122 is located adjacent to the first end 114 as described above, the first hub 130 is positioned atop the first flange 122 in registration with the inner surface 118 of the core 112, which is also in substantial registration with the fold annulus 142 of the first flange 122. The first hub 130 is then forced into the core 112, which causes the flexible fingers 124 to bend at the fold radius 142. As the first hub 130 is forced into the core 112, the flexible fingers 124 are forced against the inner surface 118.

For increased strength, an adhesive may be applied to either the flexible fingers 124 or the inner surface 118 proximate the first end 114 of the core 112 to secure the flexible fingers 124 to the inner surface 118. The first hub 130 is preferably not treated with adhesive in order to retain the convenience in subsequent disassembly. However, if necessary, adhesive may be used on the first hub 130 in some cases. The adhesive bond would then be overcome during disassembly as well as the interference fit.

The second flange 126 is secured to the core 112 in the same general manner.

Specifically, the second flange 126 is positioned adjacent to and in registration with the second end 116 of the core 112. The second hub 132 is positioned atop the second flange 126 in registration with the inner surface 118 of the core 112. The second hub 132 is then forced into the core 112, which forces the second plurality of flexible fingers 128 into the core 112 against the inner surface 118. As before, an adhesive may be applied to either the second plurality of locking fingers 128 or the inner surface 118 proximate the second end 116 of the core 112 to secure the second plurality of locking fingers 128 to the inner surface 118. The second hub 132 may also be treated with an adhesive to secure the second hub 132 to the flexible fingers 128.

The resulting reel 110 has increased structural strength over prior art paper-based reels.

While prior art reels relied upon small paper to paper gluing surfaces, or plastic to paper gluing surfaces, the present invention provides a large paper to paper gluing or adhesive surface between the flanges 122 and 126 and the core 112. Moreover, by tightly fitting the hubs 130 and 132 to the inner surface 118 of the core 112, a structurally sound reel 110 may optionally be constructed without the use of adhesive. The reel 110 further includes the benefit including disassembly features or aids created by the recessed surface 172 and corresponding slot 170.

In particular, to disassemble the reel 110, a screwdriver or other prying mechanism, not shown, is inserted axially into the axial slot 170 between the recessed surface 172 and the flexible fingers 124. The user may then leverage the prying mechanism external to the slot 170 in the radially outward direction. The prying mechanism pivots against the edge of the core 112 or possibly a portion of the hub 130 so that the portion of the prying mechanism located witliiii the slot 170 pushes the recessed surface 172 and portions of the sleeve 142 axially inward. As the sleeve 142 deforms inward, the barb members 146 clear the axial ends of the flexible fingers 124 of the flange 120 and allow the hub 130 to be partially axially removed from the core. In general, only those barbs 146 close to the prying mechanism are released and thus only a portion of the hub 130 moves axially outward with a slight tilt or skew.

The user may then repeat the same process with the prying mechanism in another axial slot 170 formed in the sleeve 142. Again, as a result of the process, another portion of the sleeve 142 is moved axially outward. The user repeats process at as many axial slots 170 on the hub 130 as is necessary to free all of the barb member 146 from the axial ends of the 124 flexible fingers of the flange 120. Once all of the barb members 146 are free, the hub 130 may readily be removed.

It will be appreciated that if adhesive is used between the core engaging surface 143 and flexible fingers 124, then the prying action described above should be break the bond of the adhesive so that the sleeve 142 can move freely. Thus, in such as case, the prying action serves to both break the adhesive bond between the flexible fingers 124 and the core engaging surface 143 and to release the barb members 146 from the interference fit with the ends of the flexible fingers.

Once the hub 130 is removed, the first flange 122 may be easily removed from the core 112 if adhesive was not used to secure the locking fingers 124 to the inner surface 118 of the core 112. If, however, adhesive had been employed, then the flange 122 cannot readily be removed because the adhesive retains the locking fingers 124 against the inner surface of the core 112. In many cases, however, it may only be necessary to remove the plastic parts of the flanges, i. e., the hub 130 for shipment for re-use. The paper portions including the flanges 122, 126 and the core may be generally recycled with other paper products. Moreover, plastic parts are typically be specially molded, whereas the paper parts are readily die cut from paperboard and/or corrugated paper. Thus, the present invention in such cases provides the advantage of allowing easy removal of the plastic hub 130, which requires special shipping and re-use procedures.

The purpose of using plastic hubs 130,132 in an otherwise paper reel allows for ease of use of the reel 110. In particular, reels are typically rotated during use. As discussed above, plastic hubs generate less friction during rotation, and are relatively hard and durable. Thus, the reel 110 features a construction that may employ substantial use of lightweight, easy to use paper products while nevertheless incorporating the benefits of plastic for rotation purposes.

The reel 110 of Fig. 1 may readily be employed by the end user by placing the reel on a rod or the like, not shown, that serves as an axle. The rod would be fixtured within the end- user's facilities. In the alternative, the reel 110 may be used in conjunction with a portable frame that may be stored in a box or the like.

Fig. 8 illustrates an implementation in which the reel 110 according to the present invention is used in a rotating reel assembly 100 supported by a portable frame. The frame may be stored and transported in a box to enable portability. Such an arrangement may be useful in construction sites or work sites where wire or some other flexible media must be obtained from a reel outside a factory setting.

The rotating reel assembly 100 consists of the reel 110 rotatably mounted on a frame.

The frame in the embodiment described in Fig. 8 includes a first end plate 134, a first static bearing 136, a second end plate 138, and a second static bearing 140. Further detail on the structure of a suitable frame having static bearings and end plates is provided in U. S Patent No.

6,234, 421, which is incorporated herein by reference.

The first static bearing 136 is fixedly secured to the first end plate 134 and the second static bearing 140 is fixedly secured to the second end plate 138. The first static bearing 136, after assembly onto the first end plate 134, is then inserted into the first dynamic bearing 144.

The second static bearing 140 is inserted into the second dynamic 147 in substantially the same manner. So assembled, the first dynamic bearing 144 is freely rotatable about the first static bearing 136 and the second dynamic bearing 147 is freely rotatable about the second static bearing 140.

The advantages of the present invention are in no way limited to the particulars of the above described embodiment. By way of illustration, Figs. 9,10 and 11 show an alternative embodiment of the present invention. This alternative embodiment includes a reel 210 that employs a single piece integrated hub and flange. Nevertheless, the alternative embodiment of the present invention enjoys the benefits of the ease of disassembly provided by the present invention.

Referring to Figs. 9,10 and 11, the reel 210 comprises a core 212, and first and second hub/flanges 230,232. The core 212 has a first end 214 and a second end 216 axially separated by the body of the core 212. The core 212 includes a inner surface 218 and an outer surface 220.

The core 212 is preferably a hollow cylindrical structure constructed of a hard material such as plastic, metal or wood. However, the core 112 may alternatively have a non-cylindrical structure, such as a hollow or partially hollow structure having a polygonal or elliptical cross section. The inner surface 218 of the core 212 includes a first set of recessed bores 250 proximate the first end 214 and a second set of recessed bores 252 proximate the second end 216. The bores 250,252 preferable extend in through the inner surface 218 but not through the outer surface 220. As such the continuity of the outer surface 220, on which the flexible media will be wound, is not compromised. However, in some cases it may be acceptable for the bores 250 and 252 to extend all the way through.

The first flange/hub 230 is secured to the first end 214 of the core 212. The second flange/hub 232 is secured to the second end 216 of the core 212.

Referring particularly to the first flange/hub 230, which shown apart from the reel 210 in Figs. 10 and 11, the first flange/hub 230 includes a disk-shaped, radial support 222 that extends radially outward from a central dynamic bearing 244 and radially past the core 212. An outer rim extends axially from the radial support 222. The dynamic bearing 244 extends axially from and defines an inner radius of the flange portion 222. The dynamic bearing 244 terminates in an inner axial edge 245. The first flange/lmb 230 is preferably constructed of a plastic material.

The first flange/hub 230 further includes a substantially cylindrical sleeve 242 disposed radially outward of the dynamic bearing 244 and which extends axially from the flange portion 222.

The sleeve 242 includes core engaging surfaces 243, recessed surfaces 272, and plug members 246. The core engaging surfaces 243 are configured to engage the inner surface of the core 218. In the embodiment described herein, the core engaging surfaces 243 form as a group a cylinder that has a radius substantially defined by the inner surface 218 of the core 212.

However, it will be noted that one or only a few core engaging surfaces may be used, so long as they still retain the sleeve 242 within the core 212.

The recessed surfaces 272 define corresponding axial slots 270 in the cylinder otherwise formed by the core engaging surfaces 243. The axial slots 270 co-extend to the axial edge of the core engaging surfaces 243, and may, but need not extend to the plug members 246. The axial slots 270 define an external access point through which a screwdriver or other prying mechanism may be disposed between the sleeve 242 and the core inner surface of the core 212.

Each of the plurality of plug members 246 engage the one of the recessed bores 250 in the inner surface 218 of the core 212. To this end, the recessed bores 250 have a shape and size configured to receive the plug members 246.

The plurality of plug members 246 secure the hub/flange 230 to the core 212 through the positive interference provided by the disposition of the plug members 246 within the recessed bores 250. If necessary, adhesive may be applied between the plug members 246 core engaging surface 243 and the inner surface 218 of the core 212 to further secure the hub/flange 230 to the core 212.

To facilitate disassembly, the plug members 246 are configured to plastically deform inward in response to radially inward pressure on the recessed surfaces 272. To this end, the recessed surfaces 272 are integrally formed with the plug members 246 and the core engaging surface 243 so that radially inward movement of the recessed surfaces 272 translates to radially inward movement of at least a portion of the sleeve that includes the plug members 246. The recessed surfaces 272 are disposed throughout the sleeve 242, preferably, but not necessarily, aligned circumferentially with the plug members 246. As with the embodiment described above in connection with Figs. 1 through 7, a prying mechanism may be inserted into the slot 270 and pressed against the recessed surface 272, causing at least one barb member 246 to clear the end of the flexible fingers 224.

The second hub/flange 232 is substantially similar and is used in a substantially similar manner.

It will be understood that the above embodiments and configurations are given by way of example only. Those of ordinary skill in the art may readily devise their own implementations that incorporate the principles of the present invention and fall within the spirit and scope thereof. For example, it is noted that embodiments are envisioned in which the core engaging surfaces of the hubs engage the outer surface of the core instead of the inner surface, or engage both the outer and inner surfaces of the core. Likewise, any protrusion of any shape that forms an interference fit may be substituted for the plug members 246 or barb members 146. It is also noted that different features from the two illustrated embodiments may be intermixed, enhanced or altered without departing from the spirit of the present invention. The claims below alone define the invention, and in no way are the words of the claims specially defined herein. The exemplary embodiments described above are nonlimiting examples.