Abstract:
A method of molding a flange uses a first tool element and a second opposing tool element. The first tool element defines a negative of at least a portion of a first side of a flange, and the second tool element defines a negative of at least a portion of the second side of the flange. The method includes providing a set of blocks for insertion into a plurality of recesses in the second tool element, the set of blocks insertable in a plurality of configurations, each configuration defining a negative of a set of retention features on the second side of the flange. The plurality of configurations define differing configurations of retention features on the second side. The method also includes inserting at least some blocks into the second tool element to form a selected one of the plurality of configurations, and performing injection molding using the first tool element and the second tool element.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/066,642, filed Feb. 22, 2008. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to reels for supporting and storing flexible media, such as cable, wire, rope, hose and the like. 
     BACKGROUND 
     Reels for supporting and storing flexible media come in many styles and sizes. In general, a typical reel includes two flanges and a core extending between the two flanges. The flexible media, which may suitably be wire, cable, rope, chain, hose or the like, is wound around the core and axially retained by the end flanges. 
     One common construction of reel consists of two flanges formed from molded plastic and a central core that is constructed of wood, metal, plastic, or paper. The flanges may be secured to the core using adhesives and/or fasteners, or may be secured to each other through the hollow core, with the core trapped between the two flanges. In the latter design, the flanges may be provided with a circular channel that is configured to receive the end of the core and hold the core in position. In this design, a long bolt secures the two flanges against the opposing ends of the core. A design of this type is disclosed in U.S. Pat. No. 5,897,075. 
     An advantage of plastic flanges is that they may readily be formed using injection molding techniques. The use of injection molding for preparing reel flanges provides the advantage of enabling the inclusion of convenience features that would be difficult or expensive to implement if the flange could not be injection molded. For example, injection molding makes it easier to include arbor holes, drive holes, and other features in a flange. U.S. Pat. No. 5,897,075 shows how features used to help align stacked reels may be easily included in a molded flange. Such flange stack features would be difficult to include in a wooden, paper or metal flange, which must be cut, assembled and/or stamped. 
     In addition, molded plastic reels exhibit a good strength-to-cost ratio. To this end, molded plastic flanges can be designed to include support ribs that allow for the overall flange width to be relatively thin while retaining strength via the ribs. 
     While plastic flanges have many advantages over their wood and metal counterparts, a drawback to the use of molded plastic reels is the cost associated with tooling. Tooling a plastic molded flange requires expertise and expense. A large percentage of the cost of a reel flange is associated with the recovery of the tooling cost. There is always a need, therefore, for reducing the cost of tooling for molded reels. 
     SUMMARY OF THE INVENTION 
     The above described drawback, as well as others, is addressed at least partially by one or more embodiments of the invention. One embodiment is a tool for use in molding a flange for use in a reel. The tool includes a first element and an opposing second element, wherein the first and second element substantially form a negative of the flange. The second element defines a negative of an inner surface of a flange, and includes a plurality of insert recesses. The insert recesses are configured to receive inserts such that the inserts define a negative of a core retention feature for the flange in a select one of a plurality of radial positions on the flange. 
     Another embodiment is a method of molding a flange using a first tool element and a second opposing tool element. The first tool element defines a negative of at least a portion of a first side of a flange, and the second tool element defines a negative of at least a portion of the second side of the flange. The method includes providing a set of blocks for insertion into a plurality of recesses in the second tool element, the set of blocks insertable in a plurality of configurations, each configuration defining a negative of a set of retention features on the second side of the flange. The plurality of configurations define differing configurations of retention features on the second side. The method also includes inserting at least some blocks into the second tool element to form a selected one of the plurality of configurations, and performing injection molding using the first tool element and the second tool element. 
     The features and advantages of these embodiments, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1   a  shows a perspective view of an exemplary first reel that incorporates flanges manufactured according to a first embodiment of the invention; 
         FIG. 1   b  shows a perspective view of an exemplary second reel that incorporates a second set of flanges manufactured according to a first embodiment of the invention; 
         FIG. 2  shows a top plan view of a flange according to an embodiment of the invention; 
         FIG. 3  shows a bottom plan view of the flange of  FIG. 2 ; 
         FIG. 4  shows a side plan view of the flange of  FIG. 2 ; 
         FIG. 5  shows an exemplary embodiment of a first mold element that may be used in the manufacture of the flange of  FIG. 2 ; 
         FIG. 6  shows an exemplary embodiment of a second mold element that may be used in the manufacture of the flange of  FIG. 2 , as well as examples of three different insert elements that may be used with the second mold element; 
         FIG. 7  shows a cross-sectional view of the second mold element of  FIG. 6  taken along section VII-VII; and 
         FIGS. 8 ,  9  and  10  show in further detail a top plan view of mold inserts that may be used in the second mold element of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1   a  and  1   b  illustrate a concept of a first embodiment of the invention.  FIGS. 1   a  and  1   b  show two different reels  10  and  20  having different sized cores  16  and  18 , and similar flanges  12 ,  13 ,  14  and  15 . The cores  16  and  18  of this exemplary embodiment are hollow and generally cylindrical, and may suitably be constructed of paper. The cores  16  and  18  have different diameters, which may or may not be dictated by the application for which they are to be used. Because the cores  16  and  18  are hollow, they also define an inner diameter, which is slightly smaller than their outer diameter by two times the wall thickness. 
     Each of the flanges has a first or outer side that faces axially away from the cores  16  and  18 , exemplified by the outer sides  22  and  26  of the flanges  12  and  14 . Each of the flanges also includes a second or inner side, illustrated by the inner sides  24  and  28  of the flanges  13  and  15 . The flanges  12 ,  13 ,  14  and  15  are largely identical, with the exception that the flanges  12  and  13  include features, not shown in  FIG. 1   a , on their inner sides that are positioned to engage the inner surface of the hollow core  16 , while the flanges  14  and  15  include features on their inner sides that are positioned to engage the inner surface of the hollow core  18 . 
     The flanges  12  and  13  are secured to the core  16  by any suitably method, including stapling, using adhesives, or using other types of fasteners. In some cases, the flanges  12  and  13  are fastened or glued to the core  16  directly. In other cases, the flanges  12  and  13  can be secured to each other using bolts, not shown. In such cases, the bolts extend from one flange  12  to the other flange  13  through the interior of the core  16 . When the flanges  12  and  13  are fastened to each other in this method, the core  16  is trapped in between the flanges  12  and  13 . In addition, the core  16  is retained radially at least in part by the core retaining features discussed above. In any event, several methods of fastening flanges to each other and/or to a core are well known. 
     Further detail regarding the core retaining features is provided in connection with the exemplary embodiment of the flange  12  shown in  FIGS. 2 ,  3  and  4 . In particular,  FIG. 2  shows a top plan view of the flange  12 ,  FIG. 3  shows a bottom plan view, and  FIG. 4  shows a side plan view. Reference is made to all three figures in the discussion of the flange  12  below. 
     As shown primarily in  FIG. 2 , the first side  22  of the flange  12  includes a flange face  32 , a plurality of radially extending ribs  34 , a core area  36 , an arbor hole  38 , a drive hole  40 , first and second handle holes  42 ,  44 , a radial set of bolt holes  46 , a set of inner bolt holes  52 , an outer annular rim  54 , and inner annular rims  56  and  58 . 
     The flange face  32  constitutes one side of the main body of the flange  12  and is in the shape of an annulus. The core area  36  is a disc-shaped body in the center of the annulus of the flange face  32 . The flange face  32  extends from the core area  36  radially outward in a concentric manner. The arbor hole  38  is a through-hole at the center of the core area  36 , and thus is arranged about the axis of the flange  12 . The arbor hole  38  is configured to receive an axial support from a fixture, not shown, that allows the reel  10  to rotate to wind or unwind a flexible media load. The drive hole  40  is defined in the core area  36  and is located off-center or eccentric to the central axis of the flange  12 . 
     The core area  36  in this embodiment is axially raised from the main surface of the flange face  32 . The outer annular rim  54  is also axially raised, and forms an upwardly extending annular ridge or rib that is disposed at the outermost radial edge of the flange face  32 . Similarly, the inner annular rims  56 ,  58  constitute upwardly extending rims. However, the inner annular rims  56 ,  58  are at different radial distances from the core area  36 , the distances lying between the position of the outer annular rim  54  and the core area  36 . The radial ribs  34  are axially raised ribs that extend radially from the core area  36  to the outer annular rim  54 . The radial ribs  34 , the outer annular rim  54 , and the inner annular rims  56 ,  58  all extend to substantially the same axial height from the flange face  32 . In this embodiment, a number of rim extensions or posts  60  extend axially from the radial ribs  34  to a level slightly higher than the outer annular rim  54 , and are located at a radial distance just short of the outer annular rim  54 . These extensions  60  are located to engage the outer annular rim of another similar flange facing the opposite direction and stacked on top of the flange  12 . The extensions  60  serve to facilitate stacking of reels by retaining another reel that has been stacked on the reel  10  in registration with the reel  10 . 
     The handle holes  42 ,  44  are through-holes formed in opposing positions near the edge of the flange face  32 . The handle holes  42 ,  44  are elongated in shape having an annular length sized to accommodate the width of four or five human fingers, and a radial width sized to accommodate the width of a little more than one finger. The handle holes preferably include positioning or comfort ridges  62  to help keep at least some fingers comfortably separated from each other when manipulating a heavy, loaded reel. 
     The radial set of bolt holes  46  is a set of holes configured to receive a bolt, not shown. The bolt is used to secure the flange  12  to the flange  13  when the core  16  is disposed between the two flanges  12  and  13 . As discussed above, the bolt passes through the central opening of the core  16 . 
     The flange  12  is generally configured to be molded for one of three different sizes of core. Accordingly, the set of bolt holes  46  is arranged at a select one of three radial positions indicated by the circumferences  48 ,  49  and  50 . It will be appreciated that the circumferences  48 ,  49  and  50  represent only a reference position, and do not necessarily constitute actual physical feature of the flange  12 . In this embodiment, the bolt holes  46  are arranged on the circumference that corresponds to the circumference of the core size that is intended to be used. Accordingly, on the flange  12 , the bolt holes  46  are arranged on the circumference  48  because this exemplary embodiment is configured for a core (e.g. core  16 ) having a corresponding (but not necessarily equivalent) circumference. However, in the flange  14  of  FIG. 1   b , which is configured for the core  18 , the bolt holes  46  would be arranged along the circumference  50 , which corresponds to the circumference of the core  18 . The position of the bolt holes  46  is variably configured through the use of various configurations of mold inserts, which will be discussed further below in connection with  FIGS. 5 to 7 . The radius of each of the circumferences  48 ,  49  and  50  is preferably arranged to be slightly smaller than the radius of the core with which the flange is intended to be used.  FIG. 3  shows the possible core circumferences  70 ,  71  and  72 , which correspond to the bolt hole circumferences  48 ,  49  and  50 , respectively. 
     It is noted that, alternatively, a single set of bolt holes may be provided inside the innermost possible core, for example, at circumference  48 . In such an embodiment, a single set of bolt holes is used regardless of the size core with which the flange is intended to be used. However, in the embodiment disclosed herein, the different radial bolt hole positions  48 ,  49  and  50  allows the bolts to be located at a substantially outermost radial position for each size core. Such a configuration allows for improved torque resistance when larger radius cores are employed. 
     Regardless, the inner bolt holes  52  are arranged in the core area  36  for all configurations and may be used additionally, or in the alternative. 
     As shown primarily in  FIG. 3 , the second side  24  of the flange  12  includes an inner flange face  64 , the underside detail of the core area  36 , the arbor hole  38 , the drive hole  40 , the handles  42 ,  44 , the radial set of bolt holes  46 , the set of inner bolt holes  52 , and a plurality of core retaining features  66 . 
     More specifically, the inner flange face  64  is the opposing side of the annulus-shaped body that defines the flange face  32  of  FIG. 2 . The inner flange face  64  thus extends from the core area  36  to the outer edge of the annulus. The inner flange face  64  is largely flat and smooth, which facilitates winding and unwinding of the load without damaging the load. 
     The core retaining features  66  are molded protrusions that extend axially outward from the inner flange face  64 , and are located along a select one of a plurality of circumferences  70 ,  71 ,  72 . In this embodiment, each of the core retaining features includes an axially raised feature having a substantially circumferentially oriented outer surface  86 , as well as support ribs  88  that extend radially inward from the outer surface  86 . 
     In the configuration of  FIG. 1 , the core retaining features  66  are located such that their radially outer surfaces  86  are located approximately along the circumference  70 . As discussed above, each of the circumferences  70 ,  71  and  72  has a radius that corresponds to the radius of the core intended to be used with the flange  12 . In particular, the circumferences  70 ,  71  and  72  correspond to the inner diameters of each of three available core sizes. Thus, for example, the circumference  70  is approximately equal to the inner diameter of the hollow core  16 , the circumference  72  is approximately equal to the inner diameter of the hollow core  18 , and the circumference  71  is approximately equal to the inner diameter of another core, not shown. 
     In the embodiment described herein, the core retaining features  66  are disposed only at the one of the circumferences  70 ,  71  and  72  that corresponds to the core being used. However, it will be appreciated that the core retaining features  66  may be configured such that the features may be both on the circumference  70 ,  71  and  72  corresponding to the core to be used, as well as on any circumference that is radially inward of the select circumference. Thus, if the core  16  of  FIG. 1   a  is to be used, then the core retaining features  66  may be located at the each of the circumferences  70 ,  71 , and  72 . However, if the core  18  of  FIG. 1   b  is to be used, then the core retaining features  66  are only located at the circumference  72 . Nevertheless, in the embodiment described herein, the core retaining features  66  are located at only the one circumference  70 ,  71  or  72  that corresponds to the core to be used. 
     In accordance with at least some embodiments, the position of the core retaining features  66  is variably configured through the use of various configurations of mold inserts, which will be discussed further below in connection with  FIGS. 5 to 7 . 
     An exemplary mold arrangement according to an embodiment of the invention is shown in  FIGS. 5 and 6 . The mold arrangement includes a first mold element  122  shown in  FIG. 5  and a second, opposing mold element  124  shown in  FIG. 6 . The first mold element  122  and the second mold element  124  are configured to be disposed against and opposite each other and by a mold press, not shown. When disposed against each other, the first mold element  122  and the second mold element  124  define an intermediate cavity that defines the shape and features of the flange  12 , as is known in the art. Molten material such as a plastic material is injected into this mold cavity as is well known in the art. 
     Referring now to  FIG. 5 , the first mold element  122  includes features that define the mold negative of most of the first side  22 , including a surface  132  that defines a negative of the flange face  32 . By “negative”, it is meant that the mold element forms an inversion of the surface of a structure such that when molten material is placed in the mold, the mold element creates that structure surface in the finished molded product. 
     The first mold element  122  also includes a plurality of radially extending notches  134  that define the ribs  34 , a negative  136   a  of the first side of the core area  36 , an arbor hole post  138  that defines the negative of the arbor hole  38 , a drive hole post  140  that defines the negative of the drive hole  40 , first and second handle hole posts  143 ,  145  that define the negatives of the first and second handle holes  42 ,  44 , a set of inner bolt hole posts  152  that defines the negative of the inner bolt holes  52 , an outer annular notch  154  that defines the negative of the outer annular rim  54 , and inner annular notches  156  and  158  that define the negatives of the inner annular rims  56  and  58 . The first mold element  122  also includes post cavities  160  within the rib notches  134  that define the negative of the rim extensions or posts  60  in first side  22  of the flange. 
     The first mold element  122  further includes three sets of radial set of bolt hole land cavities  146 ,  148  and  150 . The three sets of radial set of bolt hole land cavities  148 ,  149  and  150  are cavities located in the three possible positions of the bolt holes along circumferences  48 ,  49  and  50 . The cavities  148 ,  149  and  150  define the lands for all three sets of bolt holes (e.g. bolt hole set  46  of  FIG. 2 ), even though only one set of bolt holes will actually be formed, as discussed below in connection with  FIG. 6 . 
     It will be appreciated that since the arbor hole  38 , the drive hole  40 , the first and second handle holes  42 ,  44  and the set of inner bolt holes  52  all define voids or through-holes the flange  12 , all or some of the arbor hole post  138 , the drive hole post  140 , the first and second handle hole posts  142 ,  144  and/or the inner bolt hole posts  152  may be formed as part of the second mold element  124  instead of the first mold element  122 . 
     Referring now to  FIG. 6 , the second mold element  124  is shown in plan view.  FIG. 7  shows the mold element  124  along section VII-VII of  FIG. 6 . Reference is made to both  FIGS. 6 and 7  for discussion of the second mold element  124 . The second mold element  124  generally includes a negative of the relatively smooth inner flange face  64 , and a feature  136   b  that defines the negative of the underside of the core area  36 . The second molded element  124  includes a plurality of cavities  202  configured to receive at least some of a plurality of mold inserts  204 ,  206  and  208 . The plurality of cavities  202  and the mold inserts  204 ,  206  and  208  may be arranged in a plurality of configurations, each corresponding to one of the possible positions of the core retaining features  66  of the flange  12  (see  FIG. 3 ). To this end, each mold insert  204 ,  206  and  208  includes a negative  210   a ,  210   b ,  210   c  of the core retaining feature  66  disposed at a different relative position. 
     In this embodiment, a set of eight substantially identical mold inserts are placed within the cavities  202  for each configuration. Each set of eight substantially identical mold inserts has the shape of one of the inserts  204 ,  206  and  208 . As a consequence, if the flange  12  is to be set up to accommodate a first size core, then eight mold inserts having the design of the insert  204  are placed in to the cavities  202 . If the flange  12  is to be set up to accommodate a second size core, then eight mold inserts having the design of the insert  206  are placed in to the cavities  202 . If the flange is to be set up to accommodate a third size core, then eight mold inserts having the design of the insert  208  are placed in to the cavities  202 . In the embodiment forming the flange  12  shown in  FIGS. 2 and 3 , the eight mold inserts of the shape of the insert  204  are used. 
     The mold inserts  204 ,  206  and  208  are shown only in schematic or representative form in  FIG. 6 . Further detail regarding an exemplary embodiment of the mold inserts  204 ,  206  and  208  is shown in  FIGS. 8 ,  9  and  10 , which will be referred to simultaneously herebelow. Each mold insert  204 ,  206  and  208  includes a body  216 , a respective notch  210 ,  210   b ,  210   c  that forms a negative of a core retaining feature such as the core retaining feature  66  of  FIG. 3 , a respective post  212   a ,  212   b ,  212   c  for forming a bolt through-hole (e.g. through-hole  46  of  FIGS. 2 and 3 ), and bolt holes  214 . 
     The bodies  216  of the mold inserts  204 ,  206  and  208  are substantially identical in length, width and depth such that they are interchangeably arrangable in the cavities  202 . The notches  210   a ,  210   b  and  210   c  are arranged at different positions on the body  216  of the respective mold inserts  204 ,  206  and  208  such that when the respective mold insert  204 ,  206 ,  208  is disposed within the cavity, the notches have an outermost radial surface (e.g. the negative of surface  86 ) that is substantially aligned with one of the circumferences  70 ,  71  and  72  (see  FIG. 3 ). Each of the bolt posts  212   a ,  212   b , and  212   c  are positioned on their body  216  such that they are radially inward of the outermost radial surface of their respective notch  210   a ,  210   b ,  210   c . The bolt posts  212   a ,  212   b  and  212   c  are configured to align along the respective circumferences  48 ,  49  and  50  (see  FIG. 2 ) when the blocks  216  are disposed within the cavities  202 . 
     Each notch  210   a ,  210   b  and  210   c  in this embodiment is configured to define a feature (e.g. core retaining feature  66 ) that supports and contacts the inner diameter of a correspondingly sized reel core. As discussed above, each core retaining feature  66  may suitably include a first surface  86  that is generally aligned along one of the circumferences  70 ,  71  or  72 , and inwardly extending inclined support ribs  88  to provide strengthening to the surface  86 . 
     The negative (i.e. mold structure) of the exemplary core retaining feature  66  of this embodiment is shown in further detail in  FIG. 8 . A first notch  302  defines the first surface  86  of the core engaging feature  66  that is configured to be aligned with the core. The notch  302  includes protrusion notches  304  that form radially-outward extending protrusions on the first surface  86 , not shown in  FIG. 3 . The radially extending protrusions on the first surface  86  are configured to stress, deform or partly penetrate the inner diameter of the core. This stress, deformation and/or partial penetration of the core advantageously discourages rotation of the core on the flanges once the reel is assembled. A discussion of this advantage is provided in U.S. Pat. No. 5,897,075, which is incorporated herein by reference. The negative of the core retaining feature also includes support rib notches  308  and  310 , which form the supports  88  that strengthen the first surface  86  (formed by notch  302 ) against radially inward stress. In this embodiment, the support rib notches  308  and  310  are formed at the ends of the notch  302 . 
     It will be appreciated that the core retaining features may take many forms, and need not have the particular structure dictated by the notches  302 ,  304 ,  308  and  310 . However, additional advantages are provided by this embodiment. For example, placement of the support rib  88  at the ends of the first surface  86  provides an advantage of forming a U or C-shaped structure that defines an open space for placement of the corresponding bolt through-hole (e.g. through-hole  46  of  FIGS. 2 and 3 ) in a relatively outward position. In any event, regardless of the detailed structure of the core engaging feature  66 , each notch  210   a ,  210   b ,  210   c  is formed as the negative of the feature  66 . 
     The bolt holes  214  are aligned with corresponding bolt holes  203  located within the cavities  202  (see  FIG. 6 ). The bolt holes  214  are configured to receive a bolt or fastener, not shown, that removably fastens the inserts  204 ,  206  and  208  to the second mold element  124  within the cavities  202 . 
     In use, the mold elements  122 ,  124  are configured for making flanges of a particular known core size. To this end, eight inserts having the configuration of a select one of insert  204 ,  206  or  208  are secured into the cavities  202  via fasteners/bolts, not shown. In this example, it is assumed that eight mold inserts having the shape of the mold insert  204  are used to generate the flange  12 , which is designed for use with the core  16  of  FIG. 1 . 
     So configured, the first mold element  122  and the second mold element  124  are then used for injection molding using ordinary methods. For example, the mold elements  122  and  124  are compressed together within a mold press using any suitable technique. When compressed together, the mold elements  122 ,  124  form a mold cavity having the negative shape of the flange  12 . Molten material such as plastic is then injected into the mold cavity using any suitable methods. After set-up and cure, the mold elements  122 ,  124  are released and the substantially finished flange is ejected from the mold. Molding using opposing mold elements is well-known. 
     A reel such as the reel  10  of  FIG. 1   a  may then be assembled using two flanges having the shape of the flanges  12 . A core (e.g. core  16 ) having the size suited for the location of the core retaining features  66  is placed between the two flanges  12  such that each end of the core  16  fits over and engages the core retaining features  66 . The flanges  12  are then preferably bolted to each other (with the core  16  in between) using long bolts and the through-holes  46 . 
     It is noted that the mold comprising the mold elements  122  and  124  configured as described above may be reconfigured to produce flanges to be used with a differently sized core, such as the flanges  14  or  15  of  FIG. 1   b . To this end, the removable inserts  204  are removed from the second mold element  124  and replaced with the removable inserts  208 . Once the removable inserts  208  are secured (via bolts or the like) within the cavities  202  of the second mold element  124 , the injection molding operation is repeated. In this case, the finished flange  14  (or  15 ) has core retaining features  66  that are in a different position, due to the different design of the mold insert  208 . 
     It will therefore be appreciated that the mold element  124  may be configured to generate flanges configured for use with cores of different shape using different combinations of mold inserts. This allows a single mold tool (elements  122  and  124 ) to be used where multiple mold tools may have been required in the past. 
     It will be appreciated that the mold inserts and mold element may be configured in a number of alternative ways to achieve at least some of the advantages of the above described embodiment. For example, instead of a single set of cavities  202  arranged in an annular fashion, the second mold element may include a different set of cavities corresponding to each different circumference or core size. For example, there may be a set of cavities at about each of the circumferences  70 ,  71  and  72  of  FIG. 3 . The mold inserts in this case may include one set of inserts defining a core engaging surface, and remaining sets of inserts defining relatively flat surfaces. The set of inserts defining the core engaging features may be placed in the set of cavities at the circumference  70 ,  71  or  72  corresponding to the core to be used, while the flat inserts are placed in the other sets of cavities. 
     It will also be appreciated that the core engaging features  66  may take other forms, such as a post, a set of posts, or other structures. Such structures preferably include anti-rotation features of some kind, but it will be appreciated that many advantages of the present invention may be achieved without including protrusions (e.g. those formed by notches  304 ) that inhibit rotation of the core. 
     It will further be appreciated that the handles  42 ,  44  are placed and shaped for ergonomic comfort. However, advantages of the invention may be obtained in the absence of handles, or with handles lacking some or all of the ergonomic features of the handles  42 ,  44 . Conversely, the advantages of the handles  42 ,  44  may be obtained without employing a configurable mold element having replaceable inserts. 
     In addition, while the exemplary embodiment shows tool elements that may be configured for three different sizes of cores, it will be appreciated that the invention may readily be adapted for two, four or other amounts of different sizes of cores. 
     Thus, it will be appreciated that the above described embodiments are merely exemplary, and that those of ordinary skill in the art may readily devise their own implementations and modifications that incorporate the principles of the present invention and fall within the spirit and scope thereof.