Spinning reel spool support structure

A retainer member has a retainer portion, a through hole, and non-circular cross section. A bearing section is disposed on an outer periphery of the retainer portion. The through hole has a circular axial cross section and an inner periphery, which is axially penetrated by a non-circular portion of a spool shaft from back to front. The non-circular cross-sectional portion is formed by cutting out a front end of the retainer portion by machining. The non-circular cross-sectional portion has a non-circular axial cross section that engages the non-circular portion of the spool shaft.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese Patent Application No. 2010-011823 filed on Jan. 22, 2010, the entirety of which is hereby incorporated by reference.

BACKGROUND

Field of the Invention

The present invention relates to a spool support structure, particularly to a spinning reel spool support structure for attaching a spool onto a spool shaft in a rotatable state.

BACKGROUND ART

Conventional spinning reels include a reel unit, a rotor, and a spool. The reel unit supports a handle while allowing it to rotate. The spool is attached to a spool shaft in a rotatable state. The spinning reel spool is configured to move back and forth with respect to the reel unit. The spinning reel spool includes a bobbin trunk and a skirt. The bobbin trunk allows a fishing line to be wound around the outer periphery thereof. Further, the bobbin trunk allows a spool shaft to be attached to the inner periphery thereof. The skirt is a large-diameter tubular portion disposed on the rear end of the bobbin trunk. An annular member is disposed on the rear end of the bobbin trunk. Simultaneously, the annular member is attached onto the spool shaft while being prevented from moving. The annular member prevents the spool from moving rearward. The annular member includes a roughly-oval, i.e., non-circular, through hole in the radial inner part of the annular member. The non-circular through hole is attached onto the spool-shaft front end portion having a non-circular cross section while being prevented from rotating. In the cases of the front drag spinning reels, the bobbin trunk contains components such as a drag mechanism having a plurality of drag plates.

For example, Japan Laid-open Patent Application Publication No. JP-A-2002-204640 describes a spool of the aforementioned type attached onto a spool shaft through a bearing, e.g., a ball bearing, in a rotatable state. A bearing of this type is disposed in the inner periphery of the bobbin trunk. Simultaneously, the bearing is attached onto the outer periphery of the spool shaft while being prevented from rotating. Further, the inner periphery of the bearing is retained by a tubular retainer member having a circular hole. The retainer member abuts the annular member with the rear end thereof while being pressed rearward by the bobbin trunk. Further, the retainer member includes a through hole intersecting the spool shaft. On the other hand, the spool shaft includes a female threaded portion communicating with the through hole of the retainer member. A pin member, e.g., a hexagonal socket locking screw, is screwed into and penetrates through the through hole of the retainer member and the female threaded portion of the spool shaft. The retainer member is thereby fixed to the spool shaft while being prevented from rotating. The retainer member herein abuts the annular member with the rear end thereof for preventing the spool from moving rearward. Therefore, the drag plates can be pressed rearward by activating the drag mechanism.

In some cases, an angler loosens the drag mechanism of the spinning reel of this type to employ tactics for catching fish and the like in actual fishing. When the drag mechanism is loosened, the drag plates, having pressed rearward, reduce backward pressure. When the pressure of the drag plates is reduced, the bobbin trunk reduces pressure for pressing the retainer member rearward. Accordingly, wobble may occur between the retainer member and the spool. This is because the spool shaft, having a non-circular cross section, penetrates the circular hole of the retainer member and the structure produces a pair of roughly arched clearances between the retainer member and the spool shaft. Wobble in the retainer member may block smooth back-and-forth movement of the spool.

To solve the aforementioned drawback, Japan Laid-open Patent Application Publication No. JP-A-2005-000103 describes a spinning reel with a wobble prevention member attached to clearances between a circular portion of a retainer member and a non-circular portion of a spool shaft. The wobble prevention member herein has a cross section matched with the shape of the clearances. According to the spinning reel, clearances can be reduced between the circular portion of the retainer member and the non-circular portion of the spool shaft with the structure that the wobble prevention member, having the cross section matched with the cross-sectional shape of the clearances, is attached to the clearances. Therefore, wobble of the retainer member can be prevented.

According to the aforementioned spinning reel of the well-known type, clearances can be reduced between the circular portion of the retainer member and the non-circular portion of the spool shaft with the structure that the wobble prevention member, having a cross section matched with the cross-sectional shapes of the clearances, is attached to the clearances. In this case, however, the wobble prevention member is an individual component separate from the retainer member.

Therefore, the number of components is increased in the entire spool. Simultaneously, a large number of steps is required for assembling the spool. As a result, manufacturing cost of the spool may be increased. Further, very small clearances are produced between the circular portion of the retainer member and the non-circular portion of the spool shaft. Therefore, a very thin wobble prevention member is desirable for fitting into the small clearances. In other words, it is difficult to form the wobble prevention member suitable for the above conditions.

In view of the above, it will be apparent to those skilled in the art from this disclosure that there exists a need for an improved spinning reel with a spinning reel spool support structure to prevent easily and reliably wobble of a retainer member in a spinning reel spool. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

SUMMARY

A spinning reel spool support structure according to a first aspect is movably attached to a reel unit to move in a back-and-forth direction to allow a spool to be rotatably attached onto a spool shaft having a non-circular portion with a non-circular axial cross section at least in a front end portion thereof. The spinning reel spool support structure includes a bearing section, a retainer member, and a fixation member. The bearing section is disposed on an inner periphery of the spool while supporting the spool to allow the spool to rotate. The retainer member includes a retainer portion, a through hole, and a non-circular cross-sectional portion. The retainer portion allows the bearing section to be disposed on an outer periphery thereof. The through hole has a circular axial cross section, and allows the non-circular portion of the spool shaft to penetrate axially through an inner periphery of the circular portion from back to front. The non-circular cross-sectional portion is formed by cutting out a front end of the retainer portion by machining. The non-circular cross-sectional portion has a non-circular axial cross section to allow the non-circular portion of the spool shaft to be engaged therewith. The fixation member fixes the retainer member to the spool shaft to prevent the retainer member from axially moving.

According to the spinning reel spool support structure of the first aspect, the retainer member is formed by cutting out the front end of the retainer portion by machining. The retainer member includes the non-circular cross-sectional portion having a non-circular axial cross section to allow the non-circular portion of the spool shaft to be engaged therewith. The non-circular cross-sectional portion of the retainer member is herein engaged with the non-circular portion of the spool shaft. The inner periphery of the retainer member and the non-circular portion of the spool shaft can be fitted without any clearance. The structure prevents wobble of the retainer member. Further, the non-circular cross-sectional portion is formed by cutting out the front end of the retainer portion by machining. Therefore, the inner diameter (or the outer diameter) of the retainer portion can be shared as the common processing reference for the outer diameter (or the inner diameter) of the retainer member and the non-circular cross-sectional portion. The non-circular cross-sectional portion can be thereby easily formed with high accuracy. Consequently, wobble of the retainer member can be prevented easily and reliably.

Further, it may be assumed that the non-circular cross-sectional portion is formed by press work or injection molding. However, the following drawbacks occur when press work or injection molding is used. Simply put, a round/chamfered edge is produced by punching the retainer member in press work, whereas a tapered edge is produced by removing the retainer member from a die/dies in injection molding. Therefore, a pair of surfaces of the non-circular cross-sectional portion, engaged with the non-circular portion of the spool shaft, may be slanted without being parallel to each other. According to the structure disclosed herein, in contrast, the non-circular cross-sectional portion is cut out by machining. Therefore, the engaged surface of the non-circular cross-sectional portion with the non-circular portion of the spools shaft can be formed with high accuracy without producing the aforementioned drawbacks related to press work and injection molding. Thus, wobble of the retainer member can be further reliably prevented with the non-circular cross section formed with high accuracy

A spinning reel spool support structure according to a second aspect relates to the spinning reel spool support structure according to the first aspect, wherein the non-circular cross-sectional portion has a cut-out shape radially penetrating the front end of the retainer portion. According to the spinning reel spool support structure of the second aspect, the non-circular cross-sectional portion can be processed without greatly limiting the size of a machining tool. Simultaneously, the other portion of the spool shaft, excluding the non-circular portion, is prevented from easily interfering with the other portion of the non-circular cross-sectional portion, excluding the non-circular cross section, only by processing the non-circular cross section of the non-circular cross-sectional portion with high accuracy.

A spinning reel spool support structure according to a third aspect relates to the spinning reel spool support structure according to one of the first and second aspects, wherein the non-circular cross-sectional portion is formed by milling. According to the spinning reel spool support structure of the third aspect, the non-circular cross-sectional portion can be easily formed with high accuracy, especially when the non-circular cross-sectional portion includes a pair of parallel-opposed surfaces.

A spinning reel spool support structure according to a fourth aspect relates to the spinning reel spool support structure according to one of the first to third aspects, wherein the non-circular cross-sectional portion has a cut-out shape including a pair of parallel-opposed surfaces. According to the spinning reel spool support structure of the fourth aspect, wobble of the retainer member can be prevented easily and reliably by forming the non-circular portion of the spool shaft in a roughly oval shape including a pair of parallel surfaces and by engaging the parallel surfaces of the spool-shaft non-circular portion with the parallel-opposed surfaces of the non-circular cross-sectional portion.

A spinning reel spool support structure according to a fifth aspect relates to the spinning reel spool support structure according to one of the first to fourth aspects, wherein the bearing section includes a first bearing and a second bearing disposed rearward of the first bearing. Further, the retainer portion includes a first retainer portion and a second retainer portion. The first retainer portion has the non-circular cross-sectional portion on a front end thereof. The first retainer portion allows the first bearing to be disposed on an outer periphery thereof. The second retainer portion is disposed rearward of the first retainer portion. The second retainer portion allows the second bearing to be disposed on an outer periphery thereof. According to the spinning reel spool support structure of the fifth aspect, the spool can be stably supported by two bearings, i.e., the first and second bearings.

A spinning reel spool support structure according to a sixth aspect relates to the spinning reel spool support structure according to the fifth aspect, wherein the spinning reel spool support structure further includes a disc portion disposed between the first retainer portion and the second retainer portion. The disc portion includes an outer periphery having a diameter greater than the diameters of the first and second retainer portions. According to the spinning reel spool support structure of the sixth aspect, the first bearing and drag plates are allowed to be disposed forward of the disc plate, whereas the second bearing is allowed to be disposed rearward of the disc portion.

A spinning reel spool support structure according to a seventh aspect relates to the spinning reel spool support structure according to one of the fifth and sixth aspects, wherein the first retainer portion further includes a through hole allowing the fixation member to penetrate therethrough. According to the spinning reel spool support structure of the seventh aspect, the non-circular cross-sectional portion and the through hole are formed in the first retainer portion. Therefore, the through hole can be further easily formed relative to a structure in which the non-circular cross-sectional portion is formed in the first retainer portion and the through hole is formed in the second retainer portion.

Overall, according to the structure disclosed herein, the retainer member is formed by cutting out the front end of the retainer portion in the spinning reel spool by machining. Further, the retainer member includes the non-circular cross-sectional portion having the non-circular axial cross section to allow the non-circular portion of the spool shaft to be engaged therewith. Therefore, wobble of the retainer member can be prevented easily and reliably.

DETAILED DESCRIPTION OF THE EXEMPLARARY EMBODIMENTS

As illustrated inFIG. 1, a spinning reel, according to an exemplary embodiment, includes a handle1, a reel unit2, a rotor3, and a spool4. The reel unit2supports the handle1to allow the handle l to rotate. The rotor3is rotatably supported at the front of the reel unit2. The spool4is configured to wind a fishing line onto the outer peripheral surface thereof. The spool4is disposed at the front of the rotor3while being allowed to move back and forth. The handle1is attachable to either the right side or the left side of the reel unit2.

As illustrated inFIGS. 1 and 2, the handle1includes a handle arm1b, a knob shaft1cand a handle knob1a. The handle arm1b(seeFIG. 1) is attached onto a distal end a handle shaft85(seeFIG. 2) while being prevented from rotating relative to the handle shaft85. In other words, the handle arm1band handle shaft85are integrally rotatable. The knob shaft1c(seeFIG. 1) is a stick-shaped member fixed onto a front end of the handle arm1b. The handle knob1a(seeFIG. 1) is attached onto the knob shaft1cwhile being allowed to rotate and prevented from axially moving relative to the knob shaft1c.As illustrated inFIG. 10, the handle arm1bis a stick-shaped member produced by machining of aluminum alloy. The handle arm1bincludes an arm portion86, a first attachment portion87, and a second attachment portion88. The arm portion86is a stick-shaped portion extending from the distal end of the handle shaft85in a radial outward direction of the handle shaft85. The arm portion86can be hollow. The first attachment portion87is a plate-shaped portion formed on the front end of the arm portion86for attaching the knob shaft1cthereto (seeFIG. 1). The second attachment portion88is a hemispheric portion formed on the base end of the arm portion86for attaching the distal end of the handle shaft85thereto. The arm portion86is a crank arm and the distal end thereof bends towards the reel unit2. The first attachment portion87includes a through hole87a. The stick-shaped knob shaft1c(seeFIG. 1) is inserted through and fixed into the through hole87awhile being allowed to rotate.

As illustrated inFIGS. 10 and 11, the second attachment portion88is a portion for tightly fixing the distal end of the handle shaft85to the handle arm1bby a pin member89. The second attachment portion88includes a hemisphere88a,a first protrusion88b,and a second protrusion88c.The hemisphere88ahas a hemispheric outer peripheral surface. The first and second protrusions88band88cprotrude inward from the inner surface (the surface opposed to or facing the reel unit2) of the hemisphere88a.A first through hole88dis laterally formed in the first protrusion88b,i.e., along a direction intersecting the handle shaft85and the protruding direction of the first protrusions88b,whereas a second through hole88eis laterally formed in the second protrusion88c,i.e., along a direction intersecting the handle shaft85and the protruding direction of the second protrusions88c.The first and second through holes88dand88ecommunicate with a through hole formed in the distal end of the handle shaft85(not illustrated in the figure). The handle shaft85is tightly fixed to the handle arm1bby the pin member89inserted into these three through holes that communicate with each other. The first protrusion88bincludes a first outer surface88fon the inner surface thereof, i.e., the surface opposed to or facing the reel unit2and simultaneously opposite to the outer peripheral surface of the hemisphere88a, whereas the second protrusion88cincludes a second outer peripheral surface88gon the inner surface thereof, i.e., the surface opposed to or facing the reel unit2and simultaneously opposite to the outer peripheral surface of the hemisphere88a.The first and second outer surfaces88fand88gform a hypothetical spherical surface including the hemispheric outer peripheral surface of the hemisphere88a.In other words, in three-dimensional Euclidean space, there exists a point that is located a fixed distance or substantially fixed distance from the points on the outer peripheral surface of the hemisphere88aand on the first and second outer surfaces88fand88g.Further, a tubular handle guard84is attached between the reel unit2and the inner peripheral surface of the hemisphere88awhile being disposed on the outside of the outer periphery of the handle shaft85, as depicted with a dotted line inFIG. 10. The handle guard84is attached thereon to cover entirely the first protrusion88b,the second protrusion88c,and the pin member89. In this case, the structure prevents negative impact on the appearance design of the handle1because the handle guard84entirely covers the first protrusion88b,the second protrusion88c,and the pin member89as well as a T-slot groove formed in machining.

As illustrated inFIGS. 12 and 13, the handle knob1aincludes a tubular member90, a knob member91, and an annular member92. The tubular member90, made of synthetic rein, is attached to the knob shaft1cwhile being allowed to rotate but prevented from axially moving relative to the knob shaft1c. The knob member91, made of synthetic resin, is attached to the tubular member90while covering the outer periphery of the tubular member90. The annular member92, made of aluminum alloy, is attached onto the outer periphery of the front end of the tubular member90while being disposed in front of the knob member91. The tubular member90is made of synthetic resin such as polyacetal. The front end of the tubular member90has a roughly circular shape and allows the annular member92to be attached thereon. On the other hand, a rear portion of the tubular member90, excluding the front end, is flattened in a roughly oval shape. The outer periphery of the rear portion of the tubular member90is herein insert-molded into the knob member91. The tubular member90contains two bearings (not illustrated in the figures) in the opposed ends of the inner periphery thereof. The tubular member90is allowed to rotate with respect to the knob shaft1cthrough the bearings. As illustrated inFIGS. 13 and 14, the tubular member90includes a male threaded portion90aon the outer periphery of the end that attaches to the attachment portion87. A female threaded portion92a,formed on the inner periphery of the annular member92, is screwed onto the male threaded portion90afor attaching the annular member92to the tubular member90. Further, the annular member92is fixed to the tubular member90by an adhesive material. Thus, the tubular member90is prevented from being exposed to the outside due to attachment of the annular member92to the tubular member90. Good appearance design is thereby achieved for the handle knob1a.

As illustrated inFIGS. 12 and 13, the knob member91is a member for insert-molding the tubular member90therein. The knob member91is made of soft rubber such as PVC (polyvinyl chloride) or SEPTON™. As illustrated inFIG. 14, the tubular member90includes a first protrusion90b,a second protrusion90c,a third protrusion90d,and a fourth protrusion90eon each of a pair of opposed surfaces of the outer periphery of the roughly-oval flatted rear portion to be insert-molded into the knob member91. The first to fourth protrusions90bto90eprotrude radially outwards from each of the opposed surfaces while being axially aligned. When the outer periphery of the tubular member90is insert-molded into the knob member91, the first to fourth protrusions90bto90eserve to retain the knob member91. The knob member91, made of rubber, is accordingly prevented from being displaced radially outwards.

As illustrated inFIG. 2, the reel unit2includes a reel body2aand a lid member2b(seeFIG. 1). The reel body2aincludes a space in the inside thereof. The lid member2bis detachably attached to the reel body2ato seal the inner space of the reel body2a.Further, the reel unit2includes a reel-unit guard2dto cover the rear portions of the reel body2aand the lid member2b.

As illustrated inFIG. 2, the reel body2aincludes a T-shaped fishing-rod attachment leg2cextended upwards from the upper portion thereof in a back-and-forth direction. The reel body2ais made of light metal alloy such as magnesium alloy or aluminum alloy. As illustrated inFIG. 2, the reel body2acontains a rotor drive mechanism5and an oscillation mechanism6in the inner space thereof.

For example, the lid member2bis made of light metal alloy, e.g., magnesium alloy or aluminum alloy. As illustrated inFIG. 1, the front part of the lid member2bis fixed to the reel body2aby two fixation bolts while the fixed portions are hidden by the rotor3. On the other hand, the rear part of the lid member2b,disposed away from the rotor3, is fixed to the reel body2aby a single fixation bolt.

As illustrated inFIG. 2, the rotor drive mechanism5includes a face gear11and a pinion gear12. The face gear11is configured to rotate together with a master gear shaft10to which the handle1is fixed. The pinion gear12meshes with the face gear11. The pinion gear12has a tubular shape. The front portion of the pinion gear12is fixed to the rotor3by a nut13while penetrating through the center of the rotor3. The axial intermediate portion of the pinion gear12is supported by the reel unit2through a first bearing14awhile being allowed to rotate. Similarly, the axial rear end portion of the pinion gear12is supported by the reel unit2through a second bearing14bwhile being allowed to rotate.

As illustrated inFIG. 2, the oscillation mechanism6is configured to move a spool shaft15back and forth. The spool shaft15is coupled to the center of the spool4through a drag mechanism60for moving the spool4back and forth. The oscillation mechanism6includes a helical shaft21, a slider22, and an intermediate gear23. The helical shaft21is disposed below and parallel to the spool shaft15. The slider22is configured to move back and forth along the helical shaft21. The intermediate gear23is fixed to the distal end of the helical shaft21. The rear end of the spool shaft15is fixed to the slider22and is prevented from rotating relative to slider22. The intermediate gear23meshes with the pinion gear12.

As illustrated inFIG. 2, the rotor3includes a rotor unit7, a first cover member33, and a pair of a second cover member34and a third cover member35. The rotor unit7is allowed to rotate with respect to the reel unit2about an axis extending along the back-and-forth direction. The first cover member33covers the rear part of the rotor unit7. The second cover member34covers the outer surface of a first rotor arm31, whereas the third cover member35covers the outer surface of a second rotor arm32.

As illustrated inFIG. 2, the rotor unit7, made of aluminum alloy, for instance, is coupled to the pinion gear12while being prevented from relatively rotating. However, the rotor unit7is allowed to rotate with respect to the reel unit2. The rotor unit7includes a tubular portion30, the first rotor arm31, and the second rotor arm32. The tubular portion30includes a recess in the rear part thereof to contain a cylindrical portion formed as the front portion of the reel unit2. The first and second rotor arms31and32are connected to the opposed positions on the rear part of the tubular portion30. Each of the first and second rotor arms31and32extends forward while being separated from the tubular portion30by a predetermined distance.

As illustrated inFIG. 2, the tubular portion30includes a disc-shaped wall on the inner periphery of the front part thereof. Further, the wall includes an annular boss on the center thereof. The boss is connected to the pinion gear12while being allowed to rotate unitarily with the pinion gear12. The front part of the pinion gear12is engaged with the center of the boss while being prevented from relatively rotating. Further, the nut13is screwed onto the distal end of the pinion gear12. The rotor unit7is thereby fixed to the pinion gear12. As illustrated inFIG. 2, a fifth bearing58is disposed between the inner periphery of the tip of the nut13and the outer periphery of the spool shaft15. Further, a collar member59, made of brass, is interposed between the inner periphery of the fifth bearing58and the outer periphery of the spool shaft15, as illustrated inFIG. 9.

As illustrated inFIG. 9, the fifth bearing58is a ball bearing including an inner race58a,an outer race58b,and rolling elements58c.The inner race58ais disposed on the outer peripheral side of the spool shaft15. The outer race58bis disposed onto the inner periphery of the tip of the nut13. The rolling elements58care balls disposed between the inner race58aand the outer race58b.As illustrated inFIG. 9, the collar member59includes a tubular portion59a,a protruding portion59b, and a tightly fitting portion59c.The protruding portion59cprotrudes radially outwards from the base end, i.e., the right-side end inFIG. 9, of the tubular portion59ato make contact with the base end of the inner race58aof the fifth bearing58. The tightly fitting portion59cis a front end portion, i.e., the left-side end portion inFIG. 9of the tubular portion59afor tightly fixing the collar member59to the fifth bearing58. The tightly fitting portion59cis bent radially outwards to retain the tip of the inner race58aof the fifth bearing58under the condition that the fifth bearing58is attached onto the tubular portion59a.Thus, the fifth bearing58and the collar member59are herein attached between the inner periphery of the tip of the nut13and the outer periphery of the spool shaft15while the collar member59is tightly fixed to the fifth bearing58. Minute wobble can be herein reliably inhibited between the fifth bearing58and the collar member59due to the structure in which the collar member59is tightly fitted to the fifth bearing58.

As seen inFIG. 2, the first cover member33is structured to cover the rear part of the rotor unit7while being disposed in the surrounding of the tubular portion30. The second cover member34covers the first rotor arm31from the outside while being coupled to the first rotor arm31by a fixation bolt screwed into the first rotor arm31.

As illustrated inFIG. 2, the second cover member34is joined to the first cover member33and the first rotor arm31to form a three-dimensional curved plane. The distal end of the second cover member34is cut out in a roughly semicircular shape to dispose a first bail support member40to be described therein.

As illustrated inFIG. 2, the third cover member35covers the second rotor arm32from the outside while being fixed to the second rotor arm32by a pair of a fixation bolt and a nut member screwed onto the fixation bolt. Similarly to the second cover member34, the third cover member35is joined to the first cover member33and the second rotor arm32to form a three-dimensional curved plane. The fixation bolt herein has a function of supporting a second bail support member42(to be described) while allowing it to pivot, as well as a function of fixing the third cover member35to the rotor unit7.

As illustrated inFIG. 2, the first bail support member40is attached to the outer surface of the distal end of the first rotor arm31while being allowed to pivot relative to the first rotor arm31. A line roller41, configured to guide the fishing line to the spool4, is attached to the tip of the first bail support member40. On the other hand, the second bail support member42is attached to the outer surface of the distal end of the second rotor arm32while being allowed to pivot. A bail43, formed by bending a wire rod in a roughly U shape, is fixed between the line roller41and the second bail support member42. The aforementioned components, i.e., the first bail support member40, the second bail support member42, the line roller41and the bail43form a bail arm44for guiding the fishing line onto the spool4. The bail arm44is configured to pivot between a fishing-line guide posture illustrated inFIG. 2and a fishing-line release posture flipped from the fishing-line guide posture.

As illustrated inFIGS. 1 to 3, the bail arm44is attached to the distal ends of the first and second rotor arms31and32while being allowed to pivot between the fishing-line guide posture and the fishing-line release posture. The bail arm44includes the first bail support member40, attached to the distal end of the first rotor arm31while being allowed to pivot relative to the first rotor arm31, and the second bail support member42, attached to the distal end of the second rotor arm32while being allowed to pivot relative to the second rotor arm32.

The first bail support member40is attached to the outer surface of the first rotor arm31while being allowed to pivot relative to the first rotor arm31. Similarly, the second bail support member42is attached to the outer surface of the second rotor arm32while being allowed to pivot relative to the second rotor arm32. As illustrated inFIGS. 1 and 2, the bail arm44includes the bail43, a fixation shaft45, the line roller41, and a fixation shaft cover46. The bail43connects the first bail support member40and the second bail support member42. The fixation shaft45is fixed to the first bail support member40with the tip thereof. The line roller41is supported by the fixation shaft45. The fixation shaft cover46covers the fixation shaft45.

As illustrated inFIG. 2, the tubular portion30of the rotor3contains an anti-reverse mechanism50. The anti-reverse mechanism50is configured to prevent and to allow reverse rotation of the rotor3. The anti-rotation mechanism50includes a one-way clutch51and a switch mechanism52. The one-way clutch51is a roller clutch having an inner race configured to rotate freely. The switch mechanism52is configured to switch the one-way clutch51between an activation state, i.e., a reverse-rotation prevention state, and a deactivation state, i.e., a reverse-rotation permission state.

As illustrated inFIG. 2, the spool4is disposed between the first and second rotor arms31and32of the rotor3. The spool4is also attached to the distal end of the spool shaft15through the drag mechanism60. As illustrated inFIG. 3, the spool4includes a bobbin trunk4a,a skirt4b,a front flange4c,and a front-flange fixation member4d.The bobbin trunk4aallows the fishing line to be wound around the outer periphery thereof. The skirt4bis a tubular portion disposed behind and integrally formed with the bobbin trunk4a.The bobbin trunk4aand skirt4bcan be a one-piece unitary member. The front flange4cis a large-diameter portion attached to the front end of the bobbin trunk4a.The front-flange fixation member4dis configured to fix the front flange4cto the bobbin trunk4a.

As illustrated inFIG. 3, the bobbin trunk4aand the skirt4bform a cylindrical member with dual steps, i.e., small and large steps, obtained by forging and machining aluminum alloy, for instance. The bobbin trunk4aand the skirt4bare attached to the spool shaft15through a third bearing56and a fourth bearing57while being allowed to rotate.

As illustrated inFIG. 3, the bobbin trunk4aincludes a tubular portion16, a wall portion17, a first protruding portion18a,and a second protruding portion18b. The tubular portion16has a tubular shape and allows the fishing line to be wound around the outer periphery thereof. The wall portion17is an annular portion integrally molded with the tubular portion16while being formed on the inner peripheral side of the rear end of the tubular portion16. The first protruding portion18ais a tubular portion that protrudes forward from the wall portion17. The first protruding portion18acontains the third bearing56on the inner periphery thereof. The second protruding portion18bis a tubular portion that protrudes rearward from the wall portion17. The second protruding portion18bcontains the fourth bearing57on the inner periphery thereof. A bearing section55is made up of the third bearing56attached to the inside of the first protruding portion18aand the fourth bearing57attached to the inside of the second producing portion18b.The bearing section55is attached to the spool shaft15through a tubular retainer member70while being allowed to rotate. The retainer member70abuts a spool receiver20with the rear end thereof. The spool receiver20is attached to the retainer member70while being prevented from moving rearward relative to the retainer member70.

As illustrated inFIG. 4, the spool receiver20is a metal ring member attached to the spool shaft15while being prevented from moving back and forth relative to the spool shaft15. The spool receiver20indirectly abuts the rear end of the fourth bearing57. Even when the drag mechanism60presses the wall portion17rearward, the spool receiver20can receive the entire spool4due to the structure in which the spool receiver20is fixed to the spool shaft15.

As illustrated inFIG. 4, the retainer member70is a tubular member that abuts the spool receiver20with the rear end thereof. Further, a tubular sound producing member80has a rear end that abuts the spool receiver20on a portion radially outside the portion at which the retainer member70abuts the spool receiver20(seeFIGS. 3 and 4). The retainer member70is configured to be pressed rearward by the wall portion17. The sound producing member80is configured to produce sounds when a sound producing pin81(seeFIG. 3) repeatedly makes contact with it. The outer periphery of the retainer member70retains the bearing section55, whereas the inner periphery of the retainer member70is attached to a non-circular portion15bof the spool shaft15while being allowed to rotate unitarily with it. The non-circular portion15bis a front end portion of the spool shaft15and has a non-circular cross section. Specifically, the outer peripheral cross section of the non-circular portion15bof the spool shaft15is a roughly oval shape. The cross-sectional shape of the non-circular portion15bis obtained by longitudinally cutting a pair of opposed lateral portions of a columnar member with a pair of parallel planes.

As illustrated inFIGS. 4 to 8, the retainer member70includes a first retainer portion72, a second retainer portion73, a disc portion71, a through hole74, a through hole76, and a non-circular cross-sectional portion77. The first retainer portion72allows the third bearing56to be disposed on the outer periphery thereof. The first retainer portion72has a thick part or front end and thin part disposed behind the thick part or front end. The second retainer portion73is disposed rearward of the first retainer portion72. The second retainer portion73allows the fourth bearing57to be disposed on the outer periphery thereof. The disc portion71is disposed between the first retainer portion72and the second retainer portion73. The disc portion71has an outer periphery having a diameter greater than the diameters of either of the first and second retainer portions72and73. Further, the distance from an inner periphery to an outer periphery of the disc portion71can be greater than the respective distances of either the first and second retainer portions72and73, and can be greater than the sum of the respective distances. Further, an outer periphery of a portion of the thin part of the first retainer portion72is smaller than the outer periphery of the thick part of the first retainer portion72. The through hole74has a circular axial cross section. The through hole74allows the non-circular portion15bof the spool shaft15to penetrate axially or to pass through the inner periphery thereof when the spool shaft15is inserted therein from the rear side. The through hole76radially penetrates the first retainer portion72and allows a pin member (fixation member)75to penetrate therethrough. More specifically, the through hole76radially penetrates the thin part of the retainer portion72. The non-circular cross-sectional portion77is formed by cutting out the front end of the first retainer portion72to penetrate radially therethrough by milling. The non-circular cross-sectional portion77has a non-circular axial cross section to allow the non-circular portion15bof the spool shaft15to be engaged therewith. The retainer member70is fixed to the spool shaft15by the pin member75while being prevented from axially moving relative to the spool shaft15.

As illustrated inFIGS. 4,6and8, the first retainer portion72, the disc portion71, and the second retainer portion73are integrally molded with aluminum alloy to form a single member and to include the through hole74axially penetrating the inner radial part thereof. The alumite treatment is made for the outer peripheries of the first retainer portion72, the disc portion71, and the second retainer portion73. A plurality of adjusting washers63for adjusting a back and forth position of the spool4is disposed about an outer periphery of the first retainer portion72on the front side of the disc portion71, and abuts the front surface of the disc portion71. In other words, the adjusting washers63are disposed on an outer periphery of the thin part of the first retainer portion72and abut the front surface of the disc portion71. The second retainer portion73has an outer diameter greater than the outer diameter of the first retainer portion72. The second retainer portion73is thereby allowed to retain the fourth bearing57having a diameter greater than the diameter of the third bearing56. The through hole74is a circular through hole allowing the non-circular portion15bof the spool shaft15to pass therethrough. The through hole74has an inner diameter slightly greater than the outer diameter of a circular portion of the spool shaft15. As illustrated inFIGS. 4 to 8, the spool shaft15further includes a female threaded hole15c(seeFIG. 4) along a radial direction thereof. The female threaded hole15ccommunicates with the through hole76(seeFIGS. 5,6and8) formed in the first retainer portion72. A male threaded portion75a(seeFIG. 4) of the pin member75, e.g., a hexagonal socket locking screw, is screwed into the female threaded hole15cof the spool shaft15. The retainer member70is thereby fixed to the spool shaft15while being prevented from axially moving. The first retainer portion72includes the non-circular cross-sectional portion77on the front end thereof. The non-circular cross-sectional portion77is formed by cutting out the front end of the first retainer portion72by milling. Accordingly, the non-circular cross-sectional portion77radially penetrates or extends at the front end of the first retainer portion72. The non-circular cross-sectional portion77has a non-circular axial cross section to allow the non-circular portion15bof the spool shaft15to be engaged therewith.

As illustrated inFIGS. 4 to 8, the non-circular cross-sectional portion77is formed by cutting out the front end of the first retainer portion72by milling to produce a pair of parallel-opposed surfaces, i.e., surfaces that face or oppose and extend parallel to one another. The distance between the parallel-opposed surfaces is less than the diameter of the through hole74. As illustrated inFIGS. 5 to 7, the non-circular cross-sectional portion77is formed by cutting out the center portion of the circular front end of the first retainer portion72in a roughly oval shape. Accordingly, a pair of symmetric roughly arc-shaped portions (seeFIGS. 6 and 7) is left on the both lateral sides of the cut-out center portion of the first retainer portion72. As illustrated inFIG. 5, a distance between a pair of the parallel-opposed surfaces of the non-circular cross-sectional portion77is set to be the same as the distance between a pair of the parallel surfaces of the non-circular portion15bof the spool shaft15. Accordingly, a pair of the parallel-opposed surfaces of the non-circular cross-sectional portion77is allowed to be fitted with a pair of the parallel surfaces of the spool-shaft non-circular portion15bwithout a clearance. Thus, when assembled, the parallel-opposed surfaces of the non-circular cross-sectional portion77firmly contacts the spool-shaft non-circular portion15b.The non-circular cross-sectional portion77is formed by milling a pair of opposed surfaces based on the outer diameter (or the inner diameter) of the first retainer portion72as a processing reference. In this case, the outer diameter (or the inner diameter) of the first retainer portion72can be shared as the common processing reference for a pair of the parallel-opposed surfaces of the non-circular cross-sectional portion77and the inner diameter (or the outer diameter) of the first retainer portion72. Therefore, the engaged portion of the non-circular cross-sectional portion77with the non-circular portion15bof the spool shaft15can be easily formed with high accuracy.

As illustrated inFIGS. 2 and 3, the skirt4bis integrally or unitarily molded in a tubular shape with the bobbin trunk4ato cover the tubular portion30of the rotor3. The skirt4bis formed by processing a thin metal plate obtained by drawing of aluminum alloy.

As illustrated inFIG. 3, the front flange4cis a scratch-resistant annular member made of metal or hard ceramics. The front flange4cis slanted to expand the diameter thereof foreward. The front flange4cis interposed and fixed between the bobbin trunk4aand the front flange fixation member4d.The front flange fixation member4dis screwed into a female threaded portion formed on the front-end inner periphery of the tubular portion16of the bobbin trunk4a.

As illustrated inFIG. 3, the front flange fixation member4dincludes a tubular male threaded portion on the rear-end outer periphery thereof. The male threaded portion is screwed into the female threaded portion of the bobbin trunk4a. The male threaded portion is allowed to contain the plural drag plates62of the drag mechanism60in the inner peripheral space thereof.

As illustrated inFIG. 2, the drag mechanism60is configured to brake rotation of the spool4. The drag mechanism60includes a drag regulation knob61and the drag plates62. The drag regulation knob61is screwed onto a male threaded portion15a(seeFIG. 5) formed on the tip of the spool shaft15. The drag plates62are configured to brake the spool4when pressed by the drag regulation knob61.

Next, operations and actions of the spinning reel will be explained.

In casting, the bail arm44is flipped to the fishing-line release posture and the first and second bail support members40and42are thereby pivoted. Under this condition, an angler casts a fishing rod while hooking the fishing line with the index finger of his/her hand grasping the fishing rod. The fishing line is accordingly released with high momentum due to the weight of a tackle. When the handle1is rotated in the fishing-line winding direction after the tackle lands in water, the rotor drive mechanism5rotates the rotor3in the fishing-line winding direction. A bail tripping mechanism (not illustrated in the figures) returns the bail arm44to the fishing-line winding posture. Reverse rotation of the rotor3is thereby prevented. Accordingly, release of the fishing line is stopped.

When winding the fishing line, the handle1is rotated in the fishing-line winding direction. Rotation of the handle1is transmitted to the rotor3through the face gear11and the pinion gear12. The rotor3is accordingly rotated. When the rotor3is rotated, the fishing line, guided to the line roller41, is wound onto the spool4.

According to the foregoing spool4, the retainer member70includes the non-circular cross-sectional portion77. The non-circular cross-sectional portion77is formed by cutting out the front end of the first retainer portion72by milling. The non-circular cross-sectional portion77radially penetrates or extends at the front end of the first retainer portion72. The non-circular cross-sectional portion77has a non-circular axial cross section to allow the non-circular portion15bof the spool shaft15to be engaged therewith. Thus, the non-circular cross-sectional portion77of the retainer member70is formed to engage with the non-circular portion15bof the spool shaft15. Therefore, the inner periphery of the first retainer portion72and the non-circular portion15bof the spool shaft15can be fitted without any clearance.

This prevents wobble of the retainer member70. Further, the non-circular cross-sectional portion77is herein formed by cutting out the front end of the first retainer portion72by milling for radially penetrating the front end of the first retainer portion72. Simultaneously, the non-circular cross-sectional portion77includes a pair of parallel-opposed surfaces. Therefore, the outer diameter (or the inner diameter) of the first retainer portion72can be shared as the common processing reference for a pair of the parallel-opposed surfaces of the non-circular cross-sectional portion77and the inner diameter (or the outer diameter) of the first retainer portion72. Therefore, the engaged portion of the non-circular cross-sectional portion77with the non-circular portion15bof the spool shaft15can be easily formed with high accuracy. Consequently, wobble of the retainer member70can be prevented easily and reliably.

Other Exemplary Embodiments

(a) The shallow spool has been exemplified in the aforementioned exemplary embodiment. However, the spool of the present invention is not limited to the above. The present invention is applicable to any other suitable spinning-reel spools.

(b) In the aforementioned exemplary embodiment, two bearings, i.e., the third and fourth bearings56and57, are used as the bearing section55. However, the bearing section55is not limited to the above. For example, only a single bearing may be used as the bearing section55.

(c) In the aforementioned exemplary embodiment, the pin member75, e.g., a hexagonal socket locking screw, is used for fixing the retainer member70to the spool shaft15. However, the method of fixing the retainer member70to the spool shaft15is not limited to the above.

(d) In the aforementioned exemplary embodiment, the spool receiver20is a metal ring member. However, the spool receiver20may include a convexo-concave portion on the periphery thereof. Further, the spool receiver20may be provided with a sound producing mechanism configured to make contact with the convexo-concave portion of the spool receiver20in conjunction with rotation of the spool4.

(e) In the aforementioned exemplary embodiment, the non-circular cross-sectional portion77is formed by milling. However, the non-circular cross-sectional portion77may be formed by any other suitable machining methods.

(f) In the aforementioned exemplary embodiment, the non-circular cross-sectional portion77is cut out to have a pair of the parallel-opposed surfaces. However, the shape of the non-circular cross-sectional portion77is not limited to the above as long as the non-circular cross-sectional portion77is formed by cutting out the front end of the first retainer portion72by machining to have a non-circular axial cross section allowing the non-circular portion15bof the spool shaft15to be engaged therewith.