Abstract:
A compressible reel that includes two flanges, a flange connector, and two core wraps, where the flange connector and core wraps include scoring such that the compressible reel may be compressed substantially flat.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 61/770,644, filed on Feb. 28, 2013. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to cord reels for storing electrical and other cords. 
       BACKGROUND 
       [0003]    Long, bulky electric cords are unwieldy items for storage. They are easily tangled if compressed into a box, but take up too much space if laid out outside of a box to avoid tangling. A common solution to this problem is to wrap the cord around a large reel. These reels are generally made of three pieces of rigid plastic—a cylindrical core and two sides on either side of the core. Although such plastic reels address the problem of electric cord storage, as they are rigid and not compressible, they take up a fairly large volume considering the relatively small amount of material inherent in the product. This means that manufacturers have to ship out large volumes with relatively few products within the volume; sellers have to designate a large amount of space for display and storage of items that are fairly inexpensive; and if the end user owns one or more of the product but is not using it, he or she must also designate a fairly large amount of space for storage without utility. Therefore there is a need for a reel sturdy enough to store long, bulky electric cords when in use, but that is compressible while not in use, such as during shipping or storage without an electric cord. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention is a compressible reel. In its most basic form, the compressible reel of the present invention includes two flanges, a flange connector, and two core wraps, where the flange connector and core wraps include scoring such that the compressible reel may be compressed substantially flat. 
         [0005]    Each component of the reel is made of a material sturdy enough to support the weight of an entire wrapped, bulky electric cord, but malleable enough to be scored for folding. The preferred material is corrugated plastic. Corrugated plastic has a grain, and the grain of the corrugated plastic of each component relative to the others is an important aspect of the reel of the present invention, as discussed below. 
         [0006]    The reel of the present invention includes two preferably substantially square, flat flanges. The length of each side of the flanges is preferably approximately 26.1″, although the sides may be longer or shorter than this length, and may not be precisely equal in length. The flanges preferably have rounded corners so as to avoid poking handlers of the reel. When it is said that the reel of the present invention includes two “substantially square” flanges, “substantially square” is referring to the possible derivations away from perfect square shape in that the sides may not be precisely equal in length and the corners may be rounded. “Substantially square” should therefore refer to perfectly square shapes, as well as shapes that may not have precisely equal length sides and/or rounded corners. 
         [0007]    Each flange includes two flange core wrap slots. The flange flaps of the core wrap come through the flange core wrap slots, as discussed below. Each flange also includes sealing proximate to the flange core wrap slots so as to seal the flange flaps of the core wrap to the flanges. This sealing is preferably metal bolts or rivets, but may be heat sealing, or any other type of sealing that will permanently affix the side flaps of the core wrap to the flanges, such as sealing by sonic welding. Each flange also includes other sealings that seal the flange to the octagon portions of the flange connector, discussed in more detail below. These sealings are preferably heat sealings, but may be metal bolts or rivets, or any other type of sealing that will permanently affix the octagon portions of the flange connector to the flanges, such as sealing by sonic welding. As mentioned above, the flanges have a grain, and this grain has a flange grain direction. The flanges preferably include a center hole, and at least one additional hole, where the center hole is preferably slightly larger than the at least one additional hole. The center hole and at least one additional hole may be used to hang the reel. The flanges also preferably include finger holes at each corner to aid in carrying the reel. 
         [0008]    The reel of the present invention also includes a flange connector. The flange connector is made of material of the same thickness as the flanges. The flange connector is a long piece of material that is wrapped around to connect with itself, and the wrapped flange connector connects the two flanges of the reel. When not wrapped, from one end to another, the flange connector is preferably approximately 45.8050″ long, but may be longer or shorter. When wrapped, the flange connector consists of two regular polygons opposite from one another, with the polygons connected by two bridges opposite from one another. The preferred polygon is an octagon, but could be any polygon, such as one with 4, 5, or 6 sides. The preferred distance between opposite sides of the preferred octagon polygon is 14.4125″, but may be greater or less than this distance. As the flange connector is initially a long piece of material, one of the octagons is split in half. Therefore the flange connector has a first end, which is a side of a first half octagon, a first bridge, an octagon, a second bridge, a second half octagon, and a second end, which is a side of the second half octagon. When wrapped, the first and second ends meet so that the first and second octagon halves form a second full octagon opposite the octagon. Each side of the octagon has a length that is preferably approximately 4.2213,″ but may be longer or shorter. It is understood that the dimensions cited above are exemplary, and that the size of the compressible reel of the present invention, including the sizes of its component parts, may vary substantially. 
         [0009]    The octagon and first and second half octagons that form an octagon when put together are connected to the centers of the flanges of the reel. Therefore in embodiments of the reel where the flanges include center and additional holes, the octagons of the flange connector have corresponding holes. The first and second half octagons share a center hole, so that each has a semicircular tab indented from the first and second ends, and when the first and second ends meet, the semicircular tabs of each half octagon form the center hole that aligns with the center hole of a flange of the reel and with the center hole of the octagon. The octagon and first and second octagon halves also include sealings with the flanges. As discussed above, these sealings are preferably heat sealings, but may be any type of sealing commonly used in the art. 
         [0010]    The first and second bridges of the flange connector connect the first half octagon and the octagon, and the octagon and the second octagon, respectively. There are four bridge single scorings between the first half octagon and the first bridge, between the first bridge and the octagon, between the octagon and the second bridge, and between the second bridge and the second half octagon. These single scorings are a single line of premade scoring across the flange connector that allow the flange connector to easily bend at these places, but is not such a deep scoring that the flange connector could be folded flat at the single scorings. Each bridge also includes a bridge double scoring parallel to the bridge single scorings along the center of each bridge. This double scoring allows the bridge to be folded essentially flat at the double scoring if some pressure is applied. Each of the bridge single scorings and bridge double scorings run perpendicular to the bridge grain direction. Each bridge also includes a connector core wrap slot along the center of the bridge, perpendicular to the bridge double scoring. The connector tabs of the core wraps are placed through the connector core wrap slots to form the reel, as discussed below. 
         [0011]    The reel of the present invention also includes two core wraps. The two core wraps are made of slightly thinner material than the flanges and flange connector. This is so that it may fold more easily. The core wraps wrap around the flange connector between the two flanges to form the reel. The core wraps include flange flaps at the center of their long sides, which are the reel flange edges and are in contact with the flanges of the reel. The flange flaps protrude through the flanges and are affixed to the flanges preferably by rivets or metal bolts, as discussed above with reference to the flanges of the reel. The core wraps include connector tabs at the center of their short sides. The connector tabs tuck into the connector core wrap slots of the bridges of the flange connector. When unwrapped the core wraps are long strips of substantially rectangular material, but for the flange flaps and connector tabs. The unwrapped core wraps are preferably approximately 29.4282″ long at their longest points, from the end of one connector tab to the end of the other, but may be longer or shorter. The core wraps are preferably approximately 11.1790″ at their widest width, from the edge of one flange flap to the edge of the other, but may be longer or shorter. 
         [0012]    The core wraps include several scorings. The core wraps include a wrap double scoring along the center of the length of the core wrap parallel to the reel flange edges, and extending through the connector tabs. This wrap double scoring is similar to the bridge double scoring of the flange connector in that it allows the core wrap to fold essentially flat when enough force is applied to the wrap double scoring. The core wrap also includes four wrap single scorings perpendicular to the wrap double scoring. Two of the wrap single scorings are disposed on either side of the flange flaps. The other two wrap single scorings are disposed on either side of the two wrap single scorings disposed on either side of the flange flaps. Each wrap single scoring is a distance away from the next that is equal to the length of one side of the octagon. As discussed above, with the preferred octagon polygon, each side of the octagon, and therefore the distance between the wrap single scorings, is approximately 4.2213″. The core wraps have a grain that has a core wrap grain direction that is parallel to the wrap double scorings and perpendicular to the wrap single scorings. 
         [0013]    The reel of the present invention may be shifted between a reel position and a compressed position. In either position, the octagon portions of the flange connector are sealed to the flanges and the flange flaps of the core wrap are disposed through the flange core wrap slots and sealed to the flanges. When the reel is in the reel position, it is ready to receive and store an electric cord or any other type of cord that may be wrapped around and stored on a reel. In this position, the core wrap is wrapped around the space between the flanges and the connector tabs of the core wrap are tucked into the connector core wrap slots. In this position, the bridge grain direction is perpendicular to both the flange grain direction and the core wrap grain direction. This antidirectionality of the bridge grain strengthens the reel at these connections where a great deal of pressure will be exerted during the reel&#39;s use. 
         [0014]    When the reel is in the compressed position, pressure is exerted on the wrap double scorings and bridge double scorings so that they fold essentially flat. As there are several layers of sturdy material pressed together, the reel is not totally flat in the compressed position, but the distance between the flanges is greatly reduced from the reel position. The ability of the compressible reel of the present invention to be compressed flat is a great improvement over prior art. This ability means that more reels may be shipped per volume from the manufacturer, that less space is used for display and storage by the seller, and that less space is used by the owner who is not using the reel. Although the reel of the present invention is envisioned primarily for use with electric cords, it is understood that the reel may be used in conjunction with a variety of products that may be dispensed by reel. 
         [0015]    Therefore it is an aspect of the present invention to provide a sturdy cord reel that may be compressed essentially flat when not in use. 
         [0016]    It is a further aspect of the present invention to provide a cord reel made of corrugated plastic and using the grain of the corrugated plastic to strengthen the reel. 
         [0017]    These aspects of the present invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, accompanying drawings, and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a top down view of a flange of the reel of the present invention. 
           [0019]      FIG. 2  is a top down view of an unwrapped flange connector of the reel of the present invention. 
           [0020]      FIG. 3  is a top down view of a flat, unwrapped core wrap of the reel of the present invention. 
           [0021]      FIG. 4  is a perspective view of the conjunction of the flange connector and core wrap of the reel of the present invention. 
           [0022]      FIG. 5  is a perspective view of the reel of the present invention in the reel position. 
           [0023]      FIG. 6  is a perspective view of the reel of the present invention in the compressed position. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Referring first to  FIG. 1 , a top down view of flange  12  is shown. Two such flanges  12  are included on either side of reel  10  of the present invention. Flange  12  is approximately square, but with rounded corners. Each side has length f of approximately 26.1″. Flange  12  includes finger holes  24 , center hole  20 , and additional holes  22 . Flange  12  also includes flange core wrap slots  26 , through which flange flaps  56  of core wrap  18 , as shown in  FIG. 3 , traverse. 
         [0025]    Flange flaps  56  are secured to flange  12  with rivets  27 . Flange  12  is secured to flange connector  16 , shown in  FIG. 2 , by heat sealings  28 . Flange  12  has flange grain direction  29 . 
         [0026]    Now referring to  FIG. 2 , a top down view of flange connector  16  is shown when it is unwrapped and flat. Flange connector  16  includes, from left to right as shown, first end  30 , first half octagon  34 , first bridge  38 , octagon  39 , second bridge  40 , second half octagon  36 , and second end  32 . Each bridge  38 ,  40  includes bridge double scoring  42 , bridge single scoring  47  on either side, and connector core wrap slot  44 . When reel  10  is in compressed position  72 , as shown in  FIG. 6 , pressure is applied to bridge double scoring  42  so that bridges  38 ,  40  essentially fold in half along bridge double scoring  42 . Connector tabs  48 ,  50  of core wrap  18 , as shown in  FIG. 3 , are tucked into connector core wrap slots  44 . Bridges  38 ,  40  also have bridge grain direction  46 , which is perpendicular to scorings  42 ,  47 . When flange connector  16  is wrapped, first and second ends  30 ,  32  meet to form a full octagon similar to octagon  39 . Each of these octagons includes center hole  20 , additional holes  22 , and heat sealings  28  that align with these features on flange  12 , shown in  FIG. 1 . Each side of octagon  39  has length b, which is approximately 4.2213″. Distance a between opposite sides of octagon  39  is approximately 14.4125″. Flange connector  16  has total length c, which is approximately 45.8050″. 
         [0027]    Now referring to  FIG. 3 , a top down view of unfolded core wrap  18  is shown. Two such core wraps  18  are included in reel  10 . Core wrap  18  is made of a slightly thinner material than flanges  12  and flange connector  16 . Core wrap  18  is rectangular but for flange flaps  56 , extending from either of the centers of the long sides of the rectangle, and connector tabs  48 ,  50 , extending from either of the centers of the short sides of the rectangle. Flange flaps  56  extend through flange core wrap slots  26  of flanges  12 , as shown in  FIG. 1 . Flange flap double scoring  58  allows flange flap  56  to be easily folded to lie flush with flange  12 . This means that in reel position  70 , as shown in  FIG. 5 , flange flap double scoring  58  is folded such that flange flaps  56 , secured to flanges  12 , are perpendicular to the remainder of core wraps  18 . In compressed position  72 , as shown in  FIG. 6 , flange flap double scoring  58  is not folded, so that each side of core wrap  18  may lie flush with flanges  12 . Flange flaps  56  are affixed to flanges  12  by rivets  27 . Connector tabs  48 ,  50  are tucked through connector core wrap slots  44  of flange connector  16 , as shown in  FIG. 2 . Wrap finger holes  60  are included to ease the removal of connector tabs  48 ,  50  from connector core wrap slots  44 , when necessary. Core wrap  18  includes wrap double scoring  52  along the center of its length and four wrap single scorings  54  perpendicular to wrap double scoring  52 , and spaced b apart down the length of core wrap  18 . Distance b of core wrap  18 , shown in  FIG. 3 , is the same as distance b of flange connector  16 , shown in  FIG. 2 . When reel  10  is in compressed position  72 , as shown in  FIG. 6 , pressure is applied to wrap double scoring  52  so that core wrap  18  folds essentially in half along wrap double scoring  52 . Core wrap  18  has core wrap grain direction  64 . Core wrap  18  has length d, which is approximately 29.4282″, and width e, which is approximately 11.1790″. 
         [0028]    Now referring to  FIG. 4 , a perspective view of connector tabs  48  of two core wraps  18  being inserted into connector core wrap slot  44  of bridge  38  of flange connector  16  is shown. It is understood that although the bridge shown in  FIG. 4  is labeled “ 38 ,” this designation is arbitrary and the bridge shown may also be bridge  40 , as shown in  FIG. 2 . Bridge double scoring  42  is shown and will fold bridge  38  in half when reel  10  is in compressed position  72 , as shown in  FIG. 6 . Wrap double scoring  52  is also shown. Wrap double scoring  52  will fold core wrap  18  in half when reel  10  is in compressed position  72 . This view clearly shows bridge grain direction  46  perpendicular to core wrap grain  64 . This antidirectionality strengthens reel  10 . 
         [0029]    Now referring to  FIG. 5 , a perspective view of reel  10  of the present invention in reel position  70  is shown. In this position, core wrap  18  is wrapped around bridges  38 ,  40  of flange connector  16  and connector tabs  48 ,  50  are tucked into connector core wrap slots  44  of flange connector  16  so that flange connector  16  is no longer visible. Wrap single scorings  54  are bent to form the octagonal shape framed by flange connector  16 . Wrap double scoring  52  is visible, but flat so that every side of core wrap  18  is perpendicular to flanges  12  on either side of core wrap  18 . Core wrap grain direction  64  and flange grain direction  29  are shown. They will be in different relation to each other depending on which side of core wrap  18  is compared. Reel  10  in reel position  70  is extremely sturdy and can easily store even very heavy and/or bulky electric cords. 
         [0030]    Now referring to  FIG. 6 , a perspective view of reel  10  of the present invention in compressed position  72  is shown. Wrap double scoring  52  is folded. Although not visible in this view, it is understood that bridge double scoring  42  is also similarly folded. If pressure were applied on top of flange  12 , reel  10  would lie essentially flat. This makes storage and shipping of reel  10  much more efficient. 
         [0031]    Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein.