A reel for supporting wound flexible media that includes first and second elements. The first element has a first flange and a first set of legs extending in a directly axially away from a first side of the first flange. The second element has a second flange and a second set of legs extending axially from a first side of the second flange. The first set of legs and the second set of legs are interleaved in a circumferential direction to form at least a portion of a core of the reel disposed between the first flange and the second flange, and around which flexible media may be wound and supported. The first set of legs is configured to snap connect with the second element.

TECHNICAL FIELD

The present disclosure relates generally to the field of reels or spools that support wound media.

BACKGROUND

Traditional reel cores consist of a hollow tube around which cable, wire or other flexible media is wound, and flanges that axially retain the media on the core. Various methods can be used for assembling the hollow tube cores to the flanges, including stapling, bolting, gluing, welding, or a combination of one or more methods. Reels can be made of plastic and/or paper products to reduce costs, and can have appreciable strength and robustness.

Moreover, it has become desirable to provide a reel in which all of the components are plastic for, among other things, ease of recycling. Thus, providing a customer with reel components that need to be assembled using staples or bolts defeats this purpose. Furthermore, it can be cost and/or space prohibitive to obtain the equipment necessary for other types of assembly, such as stapling, screwing, bolting, welding and gluing. With if any of the above-mentioned assembly methods, significant secondary assembly activity is still required to produce the reel.

Accordingly, there is a need for a reel design that reduces some of the costs associated with assembly of the reels, as well as component costs.

SUMMARY

At least some embodiments described herein address the above needs, as well as others, by providing a snap-together two-part reel wherein each flange is formed with an attached portion of the core. Two parts, each having a flange and a portion of a core, are assembled together. In various embodiments, snap together parts are used to avoid the need for additional fasteners, resulting in cost and manufacturing savings. In some embodiments, the two parts or elements have an identical structure, thereby further simplifying the manufacturing process.

A first embodiment is a reel for supporting wound flexible media that includes first and second elements. The first element has a first flange and a first set of legs extending in a directly axially away from a first side of the first flange. The second element has a second flange and a second set of legs extending axially from a first side of the second flange. The first set of legs and the second set of legs are interleaved in a circumferential direction to form at least a portion of a core of the reel disposed between the first flange and the second flange, and around which flexible media may be wound and supported. The first set of legs is configured to snap connect with the second element. In some embodiments, the second set of legs is also configured to snap connect with the first element.

In another embodiment, a reel for supporting wound flexible media includes first and second elements. The first element has a first flange and at least one axial extension extending axially from a first side thereof. Similarly, the second element has a second flange and at least one axial extension extending axially from a first side thereof. The second element has a substantially identical structure as the first element, such that they are interchangeable. The first element is configured to snap fit with the second element such that the at least one axial extension of the first element and the at least one axial extension of the second element form a core of the reel, disposed between the first flange and the second flange, and around which flexible media may be wound and supported.

The above-described features and advantages, will be readily understood by those of ordinary skill in the art by reference to the following detailed description and the accompanying drawings.

DETAILED DESCRIPTION

FIG. 1 shows a top perspective view of an apparatus 10 for supporting wound flexible media that includes a first flange 12, a second flange 14, and a core 18. FIG. 2 shows a bottom perspective view of the apparatus 10 of FIG. 1. The apparatus in this embodiment is referred to as a reel 10. FIG. 3 shows a top perspective view of a kit 5 that may be assembled into the reel 10. and FIG. 4 shows a side plan view of the reel 10 in a partially assembled state. The reel 10 is configured to support wound flexible media such as electrical cable, optical fiber, and the like. The core 18 is tube structure, which in this embodiment is round and cylindrical, around which the flexible media, not shown, may be wound. Each of the flanges 12, 14 is in the form of a disk or annulus.

More particular, with reference to FIGS. 1 through 4, the flange 12 has an inner or first side 12a, and an outer or second side 12b. The flange 12 has a main plate 12c, and has a plurality of annular and radial ribs and other molded structures 12d extending axially outward from the main plate 12c on the second side 12b. The structures 12d are configured to provide strengthening and other advantages that would be known to those of ordinary skill in the art. In this embodiment, the flange 14 is substantially identical, having a corresponding inner or first side 14a, an outer or second side 14b (not visible in FIGS. 1 through 4), a main plate 14c and molded ribs and other structures, also not visible in FIGS. 1 through 4). Both flanges 12, 14 have holes for winding, handling and/or other purposes. While the flanges 12, 14 in the exemplary embodiment of the reel 10 are circular, flanges in other embodiments may take different shapes. By “substantially identical”, it is meant that the flanges 12 and 14 are interchangeable, such that the reel 10 may be made of two flanges 12, or two flanges 14. In some cases, the flanges 12 and 14 are made by the same mold

FIG. 3 shows the unassembled reel 10, which forms a kit 5 which may be subsequently assembled. With specific reference to FIGS. 2 through 4, the reel 10 is formed of a first element 30 and a second element 32. The first element 30 includes the flange 12 rigidly affixed to a partial core 40. The first element 30 is preferably formed from a single piece of injection molded plastic. Similarly, the second element 32 includes the flange 14 rigidly affixed to a second partial core 42, and is preferably formed from a single piece of injection molded plastic.

With reference to FIG. 2, the partial core 40 is formed from one or more axial extensions that extend from the first side 12a of the flange 12. In this embodiment, the axial extensions comprise three legs 50, 52, 54, each comprising an arcuate plate having a respective outer arcuate surface 50a, 52a, 54a and a respective, corresponding inner arcuate surface 50b, 52b, 54b. The three legs 50, 52, and 54 are spaced apart and dispose such that their arcuate surfaces 50a, 52a, and 54a form a partial cylinder, which is the partial core 40. The partial core 40 also includes three receivers 60, 62 and 64. In this embodiment, the legs 50, 52, 54 extend directly from the flange 12.

In this embodiment, the legs 50, 52, 54 are substantially identical to each other, and receivers 60, 62 and 64 are substantially identical, for reasons that will be discussed below. At a minimum, the outer arcuate faces 50a, 52a, 54a, are substantially identical to each other, and the receivers 60, 62, and 64 are substantially identical.

The second partial core 42 similarly includes three legs 150, 152, 154, each having an outer arcuate surface 150a, 152a, 154a, an inner arcuate surface 150b, 152b, 154b, and leg receivers 160, 162, 164. The receivers 160, 162, and 164 are disposed between adjacent pairs of legs 150, 152, 154. As a result, the second partial core 42 includes an alternating pattern of legs 150, 152, 154 and receivers 160, 162, 164. The second partial core 42 in this embodiment has a structure that is identical to the first partial core 40.

In this embodiment, each of the legs 50, 52, 54 extends axially from a proximal end, that is at, or proximate to, the first side 12a of the flange 12, to a distal end that is further away from the first side 12a of the flange 12. In this embodiment, each leg of the first set of legs 50, 52, and 54 extends axially substantially entirely from first flange 12 to the second flange 14. In addition, the outer arcuate surfaces 50a, 52a, 54a in this embodiment have arcuate lengths at the proximal end that are greater than arcuate lengths of the distal end. In other words, the outer arcuate surfaces 50a, 52a, 54a all get arcuately narrower as they extend away from the flange 12a.

Similarly in this embodiment, each of the legs 150, 152, 154 extends axially from a proximal end that is at or proximate to the first side 14a of the flange 14, to a distal end that is further away from the first side 14a of the flange 14. In this embodiment, each leg of the second set of legs 150, 152, and 154 extends axially from second flange 14 to the first flange 12. In addition, the outer arcuate surfaces 150a, 152a, 154a in this embodiment have arcuate lengths at the proximal end that are greater than arcuate lengths of the distal end. In other words, the outer arcuate surfaces 150a, 152a, 154a all get arcuately narrower as they extend away from the flange 14a.

In general, the reel 10 is formed by combining, connecting and/or assembling the first element 30 to the second element 32, such that the legs 50, 52 and 54 are interleaved with the legs 150, 152, and 154 in the circumferential direction to form the core 18. To this end, each of the legs 50, 52, 54 of the first element 30 is axially aligned with a corresponding receiver 160, 162 and 164 of the second element 32, as shown in FIGS. 3 and 4. The legs and receivers of the two elements 30, 32 are designed such that in such axial alignment, each of the legs 150, 152, 154 of the second element 32 is axially aligned with a corresponding receiver 60, 62 and 64 of the first element 30, as shown in FIG. 3. In this embodiment, because the legs and receivers on each element 30, 32 are the same, no particular receiver need be aligned with any particular leg.

As illustrated in FIG. 4, after alignment, the first element 30 is axially advanced toward the second element 32. In particular, each of the legs 50, 52, 54 of the first element 30 is axially advanced toward and into a corresponding receiver 160, 162 and 164 of the second element 32, and each of the receivers 60, 62 and 64 of the first element 30 is advanced toward and onto a corresponding leg 150, 152, 154 of the second element 32, as shown in FIG. 4. Connecting features of the legs and receivers then engage to secure (e.g. snap connect) the first element 30 to the second element 32 to form the completed reel 10, as shown in FIG. 1. Once assembled, the outer arcuate faces 50a, 52a, 54a, 150a, 152a, and 154a cooperated to form a cylindrical or other rounded tube, which is the core 18 of the reel 10.

FIG. 5 shows a fragmentary cutaway view of the reel 10 showing the interconnection of one of the legs 150 with the receiver 62. With reference to FIGS. 3 and 5, the leg 150 includes its arcuate plate 70, a connection shaft 72 and a connector 74. The arcuate plate 70 defines the outer arcuate surface 150a and the arcuate inner surface 150b. The arcuate plate 70 and the surfaces 150a, 150b, extend arcuately from a first edge 80 to a second edge 82. As discussed above, the arcuate plate 70 extends substantially the axial length of the core 18 in this embodiment, from a proximal end 84 that is adjacent and attached to the flange 14, to the distal end 86.

The connection shaft 72 is disposed on the arcuate inner surface 154b and extends at least along a part of the inner surface 150b towards and to the distal end 86. The connector 74 extends from the connection shaft 72 beyond the distal end 86 of the plate 70. The connection shaft 72 in this embodiment has opposing long edges 72a, 72b that slightly converge towards each other as the connection shaft 72 continues toward the distal end 86. As shown most clearly in FIG. 5, the connector 74 includes an arm 88 and a head 90 at the end of the arm 88. The head 90 extends radially inward from the arm 88, and includes retention surface or latch 92 and a chamfered forward edge 94.

With reference to FIGS. 2 and 3, the structure of the receiver 62 is provided with additional reference to the structure of the receiver 160 which has an identical structure. The same reference numbers will be used to describe the same structures on the receivers 60, 62, 64, 160, 162, and 164. Referring again generally to FIGS. 2, 3, and 5, each of the receivers 60, 160 includes first and second guiding walls 102, 104, reinforcement ribs 106, 108, a T-base 110. The guiding walls 102, 104 extend arcuately inward from opposing edges of adjacent legs. For example, the guiding walls 102, 104 of FIG. 2 extend arcuately inwardly from the edges of the legs 50, 52. The guiding walls 102, 104 define between themselves a void 112 that is configured to receive and fit with the connection shaft 72 when the reel 10 is assembled.

The T-base 110, as shown in FIG. 5 is secured to the flange 12 and includes an axially inner arm 111, an axially outer arm 113, and a cantilever 114 extending radially outward from the arms 111, 113. The reinforcement rib 106 extends in an at least partially inclined manner from the guiding wall 102 to the cantilever 114 and an axially inner arm 111. The axially outward side of the cantilever 114 includes a space 116 for receiving the head 90 of the connector 74.

As shown in FIG. 5, when the reel 10 is assembled, the latch 92 is disposed in the space 116, and engages the axially outward surface of the cantilever 114. The chamfered edge 94 assists in allowing the head 90 to advance passed the cantilever 114 during assembly. During axial insertion, some elastic deformation of the connector 74 takes place, for example, in the arm 88 as the chamfered edge 94 advances against the axially inward corner of the cantilever 114. Once cleared, the connector 74 recovers its original shape and the latch 92 extends into the space 116, where it assists in retaining the connection of the elements 30, 32 to each other.

All of the other receivers 160, 162, 164, 60, and 64 have the same structure. Similarly, the legs 50, 52, 54, 150, 152, 154 have the same structure. This allows the connection of the reel elements 30, 32 to be accomplished without specifically aligning the legs and receivers in a single possible axial alignment.

It will be appreciated that the orientation of the latches (e.g. latch 92) on the connectors (e.g. connector 74) of elements 30, 32, extending radially inward, can provide enhanced connection strength when the reel 10 is in use. In particular, when the reel 10 is wound with flexible media, such as optical fiber, wire or cable for example, the wound media imparts a radially inward compression force on the core 18. This further drives the latch 92 under the cantilever 114, thereby strengthening the attachment of the elements 30, 32 to each other.

FIGS. 6 and 7 show an alternative embodiment of a reel 210 (in unassembled form 205 in FIG. 7) that has the same identical structure as the reel 10, and uses the same reference numbers, except as noted below. In particular, the reel 210 includes an additional feature, a notch 130, which is formed by discontinuities of the arcuate plate edges of adjacent legs 50, 150. Specifically the notch 130 is created by cooperating discontinuities 130a, 130b disposed at the proximal end of one leg 150 and the distal end of the adjacent leg 50. The notch 130 is a feature that can be used on automated winding machines as is known in the art, for example, certain winding machines sold by Windak.

In the exemplary embodiments described above, the manufacturing process may be simplified. The elements 30, 32 reels can be snapped together to form a full reel 10 (or 210), without any extra parts or secondary off-line assembly. In some cases, the assembly can be completed at the injection molding station by the same operator who packages the reel for inventory storage and shipping.

It will be appreciated that the above-described embodiments are merely illustrative, and that those of ordinary skill in the art may readily devise their own implementations and modifications that incorporate the principals of the present invention and fall within the spirit and scope thereof. For example, it will be appreciated that more or fewer than three legs and receivers may be used in on each reel element 30, 32. It will be appreciated that the reel pieces 30, 32 need not be identical in structure, and still obtain some of the benefits of the embodiments described herein. It will also be appreciated that the flanges 12, 14 may have different designs, and can have different shapes.