BREAKDOWN REEL

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Application No. 60/848,831 filed October 2, 2006.

BACKGROUND OF THE INVENTION

Field of the Invention

[0002] Spools or reels generally comprise a barrel and two opposing flanges. The present invention is directed to a spool on which continuous-strand products such as insulated or bare wire, cable, textile yarns, cordage, chain, etc. are wound. In particular, the invention is directed toward a spool that may be efficiently assembled and disassembled. Such spools are commonly referred to as "knockdown reels". More particularly, the present invention provides a mechanism for the assembly and disassembly of a knockdown reel in an efficient manner comprising a device for securely fastening and easily unfastening the flanges to the barrel.

Brief Description of the Related Art

[0003] There are a vast assortment of -spools available in the prior art ranging from spools on which threads are wound to spools on which chains and cables are wound. The smaller spools upon which thread and the like are wound are typically fabricated in one-piece units that are disposable. In contrast, the larger spools must

be more robust in order provide the necessary functionality required. Accordingly, these spools are constructed of more durable material and are more complex in design often comprising several components. Consequently, such spools typically are manufactured by one party and shipped to a second party that will wind a product around the spool. In order to economically and efficiently manufacture the necessary robust spool while minimizing shipping costs, manufacturers have endeavored to create innovative spool assembly and disassembly methods. [0004] Some prior art methods and devices for knockdown reels are known. These devices appear to have the advantage of disassembly for compact storage. However, most reels or spools disclosed in these references have significant differences from the present invention. Typically, knockdown reels comprise a barrel, two opposing flanges, and some sort of connecting mechanism engaging the flanges and the barrel.

[0005] For example, U.S. Patent No. 6,045,087 to Vislocky and Curtis discloses a spool assembly having a barrel with flanges that engagingly snap fit thereon. The barrel (spindle) 10, defines guiding notches 15 and 16 and locking openings 13 and 14 disposed on opposing end faces. The flanges 1 10 and 210 in turn define guiding members 1 16 and 216 to engage guiding notches 15 and 16. Hubs 112 and 212 are fixedly attached to flanges 110 and 210 and define locking members 1 14 and 214 to engage locking openings 13 and 14. (See Vislocky and Curtis, Abstract, Column 1, lines 35-48, Column 6, lines 25-49, and related Figures).

[0006] In another example, U.S. Patent No. 5,743,486 to Bulman discloses a knockdown reel comprised of a barrel (core) 11 having threaded ends 15 and end

flanges 12 threadedly attached to the threaded ends 15. Extending outward from threaded ends 15 of barrel 11 is a tapered locking ring 14. Locking ring 14 is designed to engage locking ring 19 of flanges 12 when the flanges are fully threaded on to the barrel. (See Bulman, Column 2, lines 64-67 and related Figures). It would require a "very deliberate act" to disassemble the mechanism. (See Bulman, Column 3, line 37).

[0007] U.S. Patent No. 5,143,316 to Goetz, Charles R. and Goetz, Charles G. describes yet another prior art knockdown reel that defines a barrel (spindle) 5, flanges (end plates) 2, and hubs 3 "formed integrally with each end plate". (See Goetz, Column 2, line 66). Hub 3 receives a respective end portion of barrel 5. Goetz further discloses a slide 32 that moves axially relative to the barrel and provides a subassembly that accommodates a mandrel for rotating the spool. When the slide is in a recessed position, it is located within the spool. (See Goetz, Column 3, line 59 to. Column 4, line 7).

[0008] In another prior art example, U.S. Patent No. 4,903,913 to McCaffrey discloses a knock-down spool assembly including a barrel (spindle) 50 and end plates 11 and 21 comprising flanges 12 and 22 and integrally formed hubs 16 and 26. (See McCaffrey, Column 3, lines 13-21 and lines 43-45). End portions 51 and 52 of barrel 50 define integrally formed projections 55 and 56 designed to engage openings 40a and 40b in plates 11 and 21. (See McCaffrey, Column 4, lines 28-34). [0009] U.S. Patent No. 3,822,841 to Campbell discloses one of the more typical knockdown reels known. The reel comprises a barrel (hub) 12 and flanges 14. The flanges define sockets 32 that serve as a hub for receiving the barrel. The ends of

barrel 12 define latch members 24 each having locking abutments 28 defined thereon. Locking abutments 28 engage apertures 40 of the side wall 34 of socket 32. (See Campbell, Figure 12, Column 5, lines 1-9 and lines 59-66).

[0010] U.S. Patent No. 3,552,677 to Hacker also describes a basic knockdown reel comprising a barrel (drum) 10, flanges 30 and 50, hub (collar) 38 formed within bore 42 of a flange, and locking means 50. A socket 46 is formed in the outer ends of barrel 10 and the socket forms sleeve 48. Stems 52 extend outwardly from edge 54 of sleeve 48 and are received in corresponding apertures 56 in the flange. Stems 52 define catches 58 to engage shoulders 62 formed on the hub 38. (See Hacker, Column 3, lines 31-33, and Column 3, line 58 — Column 4, line 9). [0011] Most of the prior art devices known have been designed for easy assembly but not necessarily easy and quick disassembly. As one practiced in the art knows, the prior art devices that comprises locking tabs that engage corresponding openings do not provide a robust disassembly method. Often times the tabs break rendering the entire spool useless if the tabs are integrally formed with either the hub or the barrel as is the case with most of the prior art devices. In certain applications, the method of employing simple tabs or protrusions that engage corresponding openings will not provide a suitable durable assembled spool either.

[0012] In other prior art devices wherein the hub is integrally formed with the disk, more space is required for storage or shipping such spool components than if the hub was formed as a separate component. Other prior art devices, such as those wherein the hub threadedly engages the flanges and then engages a locking mechanism, require too much time and effort to disassemble and often are discarded

after use. In addition, these prior art devices generally comprise hubs integrally formed with the disk

[0013] Based on the foregoing, a need exists for a spool or knockdown reel comprising two flanges and a barrel disposed therebetween that may be efficiently assembled and disassembled. When such a reel is assembled, continuous-strand products such as insulated or bare wire, cable, textile yarns, cordage, chain, etc. are wound around the barrel between the two flanges. Most prior art reels have to be shipped in an assembled position in order to exhibit their desired characteristics such as strength, resistance to wear arid fatigue, etc. On the other hand, prior art knockdown spools that can be shipped non-assembled and advantageously provide lower-cost shipping, handling and storage characteristics do not provide the desired strength, resistance to wear and fatigue, etc. characteristics and also require time- consuming assembly on the part of the receiver of the unassembled reels. [0014] It is an object of the present invention to overcome the shortcomings of the prior art stated above. It is another object of the present invention to provide a mechanism for the assembly and disassembly of a knockdown reel in an efficient manner. It is another object of the present invention to provide a device for securely fastening and easily unfastening the flanges to the barrel of a knockdown reel.

DESCRIPTION OF THE INVENTION

[0015] The knockdown reel of the present invention comprises a barrel, two opposing flanges, a hub that accommodates the secure fastening and easily unfastening of the flanges to the barrel. The hub, referred to herein as a locking

mechanism, is fabricated comprises two components, an inner section and an outer section. The inner section of the locking mechanism is fixedly or removeably attached to an end of the barrel as further described herein. The outer section of the locking mechanism is designed such that it comprises the device for securely fastening and easily unfastening the flanges to the barrel of a knockdown reel.

Brief Description of the Drawings

[0016] Figure 1 provides a three-dimensional rendering of a disassembled knockdown reel according to the present invention.

[0017] Figure 2 depicts a schematic representation of a disassembled knockdown reel according to the present invention.

[0018] Figure 3 provides a three-dimensional rendering of a component of the locking mechanism according to the present invention.

[0019] Figure 4 provides a three-dimensional rendering of a locking mechanism according to the present invention.

[0020] Figure 5 provides a three-dimensional rendering of another embodiment of a locking mechanism according to the present invention.

[0021] Figure 6 provides a three-dimensional rendering of another embodiment of a locking mechanism according to the present invention.

[0022] Figure 7 provides a three-dimensional rendering of another embodiment of a locking mechanism according to the present invention.

Detailed Description of the Invention

[0023] One embodiment of the device, as shown in Figures 1 and 2, comprises a spool 10 further comprising a barrel 12 and at least one flange 14. The locking mechanism 16 comprises two.components: an outside section 18 and an inside section 20. The inside section 20 is fabricated to interlock or be conjoined with the barrel 12 on one end 22. In one embodiment, the outer diameter of inside section 20 and the inner diameter of barrel 12 are conjoined via solvent welding. In another embodiment, the outer diameter of inside section 20 engages the inner diameter of barrel 12 via protruding barbs. In yet another embodiment, the outer diameter of inside section 20 threadedly engages the inner diameter of barrel 12. There are many known methods for removeably or fixedly securing inside section 20 to barrel 12 on one end 22, each of which are considered within the scope of this invention. [0024] As further shown in Figure 1 , inside section 20 exhibits a radial flange 24 which, in turn, defines an inner face 26 and an outer face 28. Face 26 is disposed toward barrel 12 and may serve to define connectivity with barrel 12. Face 28 is disposed toward flange 14 and may serve to define connectivity with flange 14. Inside section 20 further defines an inner diameter face 30 and an outer diameter face 32. Flange 14 further defines an inner diameter face 34. In this embodiment of the invention, flange 14 is brought into contact with and positioned or seated on inside section 20 radial flange 24 face 28. Flange inner diameter face 34 is brought into contact with and positioned proximate to outer diameter face 32 of inside section 20.

[0025] The novelty of the embodiment shown in Figure 1 arises with the connectivity of outside section 18 with inside section 20, both of locking mechanism 16, thereby removeably securing flange 14 to barrel 12.

[0026] Outside section 18 defines keyed elements 36 fabricated to mate with opposing elements (not shown) fabricated in inner diameter face 30 of inside section 20. Such elements provide for a secured latching mechanism assuring the connectivity of the mating pieces. The loading of the spool further assures connectivity of the pieces by applying loading such that the locking mechanism is retained in its locked position. Correspondingly, the latching mechanism permits a simple detaching of the pieces by an application of force in the opposite direction. [0027] The embodiment of outside section 18 described above with respect to Figure 1 can best be viewed in Figure 3. Keyed elements 36 exhibit click-locking protrusions 38 designed to engage click-locking receptacles 40 of inner section 20 shown in Figure 4.

[0028] As shown in Figure 5, outside section 1 18 exhibits keyed elements 136 which, in turn, define click-locking protrusions 138 designed to engage click-locking receptacles 140 of inner section 120.

[0029] Figures 6 and 7 provide diagrammatic representations of yet additional embodiments of the locking arrangement of the present invention. As shown in Figure 6, outside section 218 defines keyed elements 236 which, in turn, defines protrusions 238 and receptacle 239. The inner diameter of inner section 220 (not shown) would be fabricated to correspond with keyed element 236. As shown in Figure 7, the inner diameter of an alternative embodiment of inner section 320 can

form a variety of configurations 340 to correspond with a keyed element of the outer section of the locking mechanism.

[0030] The apertures shown in the top face 42 of outer section 18 and bottom face 44 of inner section 20, Figure 3 and Figure 4, respectively, are for manufacturing, molding and utility purposes as well as for users of the goods in commerce. The method of manufacturing locking mechanism 16 wherein the protrusions 38 and receptacles 40 can be integrally formed with outer section 18 and inner section 20, receptively, is considered within the scope of this invention. The components can be injection molded to include their respective protrusions and receptacles, or injection molded and then stamped. There are many known methods for fabricating protrusions and receptacles as disclosed above such as the use of pins, male-female receptacles, etc., each of which are considered within the scope of this invention. [0031] The knockdown reel of the present invention overcomes the shortcomings of the prior art by providing a novel mechanism for the assembly and disassembly of a knockdown reel in an efficient manner. In addition, the present invention provides a device for securely and more robustly fastening and easily unfastening the flanges to the barrel of a knockdown reel. Although the invention has been described in considerable detail with respect to particular embodiments of Applicant's locking mechanism for knockdown reels, it will be apparent that the invention is capable of numerous modifications and variations, apparent to those skilled in the art, without departing from the spirit and scope of the invention.