Abstract:
An apparatus for supporting wound flexible media includes a core, first and second flanges, and at least one locking ring. The core has first and second ends, an inner surface and an outer surface. The first flange, which attaches to the first end of the core, includes a first plurality of flexible fingers that extend axially inward the core adjacent to said inner surface proximate the first end. Likewise, the second flange, which attaches to the second end of the core, includes a second plurality of flexible fingers that extend axially inward the core adjacent to said inner surface proximate the second end. The locking ring urges the first plurality of flexible fingers to the inner surface proximate the first end.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 08/924,155, filed Sep. 5, 1997, abandoned, and also claim benefit of 60/029,113 filed Oct. 24, 1996. 
    
    
     FIELD OF THE INVENTION 
     The present intention relates generally to reels for supporting or storing flexible media. 
     BACKGROUND OF THE INVENTION 
     Reels for storing flexible media, such as wire, hose, fabric, chain link, or rope, typically comprise a core interposed between two flanges. In general, the flexible media is wound or wrapped around the core and held in place by the flanges. Reels that are intended for industrial transport, storage and use of flexible media vary greatly in size. Reels have traditionally been fabricated out of wood or metallic material, and have more recently been fabricated from paper and plastic products. 
     Ideally, a reel combines structural strength with convenience and economy of manufacture. One development in the reel industry that has increased convenience is the rotating reel assembly. A rotating reel assembly is a reel that is rotatably connected to a frame structure and is typically enclosed in a box. The rotating reel assembly permits the user of the flexible media payload to pay-out the flexible media at any location without the need for special fixtures on which to mount the reel. 
     For example, the Reel In A Box product from Carris Reels is a rotating reel assembly within a box that may be used at any suitable location. An end user simply places the box in the location in which the flexible media, for example, cable, is needed. The cable may then be started through an opening in the box and paid out as the reel rotates within box. To facilitate pay out within the box, the reel is rotatably connected to frame within the box. The frame supports and allows free rotation of the reel within the box. 
     One drawback of the Carris Reel in a Box and other presently available products is that the are constructed predominantly of non-paper materials, such as wood, metal, or plastic. Paper materials are advantageous in reel construction because paper has a better strength to weight ratio than plastics, wood and metal, and therefore is less expensive to transport and easier to manipulate. Moreover, paper products are is generally easier to recycle. The Carris Reel is a Box loses such advantages by relying predominantly on non-paper materials. 
     Another currently available rotating reel assembly, the Easy-Reel™ product from Genpak, utilizes a reel made substantially from corrugated and/or pressed paper. While the use of paper products reduces weight and is generally easier to recycle, the Easy-Reel™ product has other significant shortcomings. For example, the Genpak reel has structural weaknesses in the attachment of the flanges to the core. Specifically, the Genpak reel uses a plastic hub that connects a paper flange to a paper core. The attachment of the flange to the core relies on a plastic to paper interface, which presumably is glued. Plastic to paper glue bonds can be relatively weak. The Genpak reel also includes a small paper to paper interface consisting of the inner radial edge of the flange and the outside of the core. However, the inner radial edge of the flange provides very little paper surface area to provide the structural attachment of the flange to the core. As a result, the attachment of the flange to the core has limited structural integrity. 
     Another shortcoming of the Genpak reel is that it must be loaded to a box to be functional. Specifically, the only feature that holds the stationary reel frame to the rotating reel is the box itself. The stationary reel frame consists of two individual end plates that are held in place by the box. Without the box, the end plates may freely migrate axially out from the reel. As a result, loading the reel is an inconvenient process. In particular, a reel must first be loaded, and then carefully assembled onto the frame and placed within the box while holding the frame against the reel. Such a process is undesirable because of the difficulties associated with manipulating a loaded, and typically heavy reel. 
     A need therefore exists for a lightweight reel that has a structurally strong means by which the flanges are attached to the core. A further need exists for a rotating reel assembly that features such a lightweight and structurally sound reel. Yet a further need exists for a rotating reel assembly that does not require a box to secure the stationary reel frame to the rotating reel. 
     SUMMARY OF THE INVENTION 
     The present invention fulfills the above stated needs, as well as others, by providing a reel comprising a core, and two flanges, each flange having a plurality of flexible fingers for engaging the core to help secure the flange to the core. The plurality of flexible fingers on the flanges increase the surface area of the flange that engages the core, thereby strengthening the connection between each flange and the core. The increased engagement surface area allow the use of predominantly paper materials in a structurally strong reel. 
     In one embodiment of the present invention, an apparatus for supporting wound flexible media includes a core, first and second flanges, and at least one locking ring. The core has first and second ends, an inner surface and an outer surface. The first flange, which attaches to the first end of the core, includes a first plurality of flexible fingers that extend axially inward the core adjacent to said inner surface proximate the first end. Likewise, the second flange, which attaches to the second end of the core, includes a second plurality of flexible fingers that extend axially inward the core adjacent to said inner surface proximate the second end. The locking ring urges the first plurality of flexible fingers to the inner surface proximate the first end. A second locking ring may also be employed to urge the second plurality of flexible fingers to the inner surface proximate the second end. 
     The resulting structure provides a strong attachment of each flange to the core, particularly for reels in which the core and flanges are constructed of paper products. Another aspect of the present invention is a rotating reel assembly that incorporates the above reel. The rotating reel assembly includes the a reel having a similar structure as that described above wherein the at least one locking ring is part of at least one hub. The at least one hub also includes at least one rotating bearing. The rotating reel assembly according to the present invention further includes a frame, the frame including at least one static bearing for rotatably engaging the at least one rotating bearing to permit the reel to rotating with respect to the frame. In a preferred embodiment, the static bearing includes an axial retention surface for inhibiting axial movement of the static bearing with respect to the dynamic bearing. The axial retention surface facilitates retention of the frame to the reel, thereby allowing full use of the rotating reel assembly without a box to hold the assembly together. 
     The present invention thus provides a structurally strong reel that may be constructed out of predominantly paper materials. As a result, the advantages of paper reels may be exploited without the structural weakness typically associated with the core-flange attachment in such reels. 
    
    
     The above features and advantages, as well as others, will become 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 illustrates an elevational perspective view of an exemplary reel in accordance with the present invention; 
     FIG. 2 illustrates a cross sectional side view (not to scale) of the reel in FIG. 1; 
     FIG. 3 illustrates an exploded perspective view (not to scale) of the reel in FIG. 1; 
     FIG. 4 illustrates a flange for use in a reel according to the present invention; 
     FIG. 5 illustrates an exploded perspective view of a second embodiment of a reel according to the present invention in a rotating reel assembly according to the present invention; 
     FIG. 6 illustrates a cross sectional side view of the rotating reel assembly of FIG. 5; 
     FIGS. 7A and 7B illustrate first and second perspective views of a static bearing for use in the rotating reel assembly of FIG. 5; and 
     FIGS. 8A and 8B illustrate first and second perspective views of a hub including a dynamic bearing for use in the rotating reel assembly of FIG.  5 . 
    
    
     DETAILED DESCRIPTION 
     FIG. 1 illustrates an elevational perspective view of an exemplary first embodiment of a reel in accordance with the present invention. The reel  10  comprises a core  12 , first and second flanges  22  and  26 , respectively, and at least one locking ring  30  that serves as a hub. As will be described in further detail in connection with FIGS. 2,  3  and  4 , the first and second flanges  22  and  26 , respectively, each include a plurality of flexible fingers. The at least one locking ring  30  tightly fits into the core to trap the plurality of flexible fingers adjacent to the interior of the core  12 . 
     Reference is made to FIGS. 2 and 3, which illustrate in detail the reel  10  of FIG.  1 . FIG. 2 illustrates a cross sectional side view (not to scale) of the reel  10 , and FIG. 3 illustrates an exploded perspective view (not to scale) of the reel  10 . 
     The core  12  has a first end  14  and a second end  16  axially separated by the body of the core  12 . The core  12  includes a inner surface  18  and an outer surface  20 . In the first embodiment, the core  12  is preferably a hollow cylindrical structure constructed of rigid pressed paper material. While the use of a cylindrical structure has certain advantages, such as simplicity of manufacture, the core  12  may alternatively have a non-cylindrical structure, such as a hollow or partially hollow structure having a polygonal or elliptical cross section. 
     In any event, the first flange  22  attaches to the core  12  via a first plurality of flexible fingers  24 . Reference is additionally made to FIG. 4, which illustrates a top view of the first flange  22  apart from the reel  10 . The first flange  22  comprises a plate-like annulus having an outer perimeter  35  and a center hole  36 . Although the general circular or annular shape of the first flange  22  is preferred, other shapes may readily be used, such as elliptical or polygonal shapes. The first flange  22  comprises an inner plate  34  and an outer plate  40 . The inner plate  34  includes an inner radial edge  38  that defines the center hole  36  and engages the outer surface  20  of the core  12  (See FIGS.  2  and  3 ). The outer plate  40  includes a fold annulus  42  which defines a ring that is in registration with the inner surface  18  of the core  12  (See FIGS.  2  and  3 ). 
     As shown in FIGS. 3 and 4, prior to assembly, the first plurality of flexible fingers  24  extends radially inward the fold radius  42 . The first plurality of flexible fingers  24  are typically integrally formed with at least a portion of the annulus of the first flange  22  and in this case, the outer plate  40 . In a preferred embodiment, the first flange  22  is constructed of corrugated paper and the first plurality of flexible fingers  24  are formed by die cutting a series of annularly spaced, radial cuts extending inward from the fold radius  42  of the outer plate  40 . Once the reel  10  is assembled, the first plurality of flexible fingers  24  extend axially inward the core  12 , approximately perpendicular to the radial plane of the annulus of first flange  22  (see FIG.  2 ). 
     The second flange  26  preferably has substantially the same structure as the first flange  22 , and includes a second plurality of flexible fingers  28  formed in the same manner as the first plurality of flexible fingers  24 . 
     In the first embodiment, first locking ring  30  and a second locking ring  32  each comprise a hub that secures the flexible fingers  24  and  28  to the inner surface  18  of the core  12 . Specifically, the first locking ring  30  urges and secures the first plurality of flexible fingers  24  to the inner surface  18  proximate the first end  14 , and the second locking ring  32  urges and secures the second plurality of flexible fingers  28  to the inner surface  18  proximate the second end  16 . To this end, the first locking ring  30  and second locking ring  32  preferably have dimensions slightly smaller than, but generally defining, the inner surface  18  of the core  12 . The first and second locking rings  30  and  32 , respectively, may suitably be constructed of pressed paper or other paper material, plastic, wood, metal or a composite material. The use of paper for the first and second locking rings  30  and  32  provide the advantage of an all paper construction when the core  12  and flanges  22  and  26  are also constructed of paper. 
     During assembly, the first flange  22  is located adjacent to the first end  14  of the core  12  such that the radial edge  38  fits over the outer surface  20  of the core  12 . The first plurality of flexible fingers  24  are then forced axially inward the first end  14  of the core  12 . In a preferred assembly method, the first locking ring  30  is used to force the first plurality of flexible fingers  24  into the core  12 . In other words, after the first flange  22  is located adjacent to the first end  14  of the core  12  as described above, the first locking ring  30  is positioned atop the first flange  22  in registration with the inner surface  18  of the core  12 , which is also in substantial registration with the fold annulus  42  of the first flange  22 . The first locking ring  30  is then forced into the core  12 , which causes the first plurality of flexible fingers  24  to bend at the fold radius  42 . As the first locking ring  30  is forced into the core  12 , the first plurality of flexible fingers  24  are forced against the inner surface  18 . 
     For increased strength, an adhesive is applied to either the first plurality of locking fingers  24  or the inner surface  18  proximate the first end  14  of the core  12  to secure the first plurality of locking fingers  24  to the inner surface  18 . The first locking ring  30  may also be treated with an adhesive to secure the first hub  30  to the plurality of flexible fingers  24 . 
     The second flange  26  is secured to the core  12  in the same general manner. Specifically, the second flange  26  is positioned adjacent to and in registration with the second end  16  of the core  12 . The second locking ring  32  is positioned atop the second flange  26  in registration with the inner surface  18  of the core  12 . The second locking ring  32  is then forced into the core  12 , which forces the second plurality of flexible fingers  28  into the core  12  against the inner surface  18 . As before, an adhesive may be applied to either the second plurality of locking fingers  28  or the inner surface  18  proximate the second end  16  of the core  12  to secure the second plurality of locking fingers  28  to the inner surface  18 . The second locking ring  32  may also be treated with an adhesive to secure the second locking ring  32  to the second plurality of flexible fingers  28 . 
     The resulting reel  10  has increased structural strength over prior art paper-based reels. While prior art reels relied upon small paper to paper gluing surfaces, or plastic to paper gluing surfaces, the present invention provides a large paper to paper gluing or adhesive surface between the flanges  22  and  26  and the core  12 . Moreover, by tightly fitting the hubs or locking rings  30  and  32  to the inner surface  18  of the core  12 , a structurally sound reel  10  may optionally be constructed without the use of adhesive. 
     The reel  10  may readily be incorporated into a rotating reel assembly by adding a frame, not shown, that includes an axle or static bearings which engage and allow rotational movement of the first and second locking rings  30  and  32 , respectively. Alternatively, the reel  10  may be used as a stand-alone reel. 
     FIGS. 5 and 6 illustrate a second embodiment of a reel  100  according to the present invention in a rotating reel assembly  100  according to the present invention. The reel  110  incorporates the features and advantages of the reel  10  of FIGS. 1 through 4, but uses an alternative hub structure that provides further advantages when used in a rotating reel assembly. FIG. 5 illustrates an exploded perspective view of the reel  110  and the rotating reel assembly  100 , and FIG. 6 illustrates a cross sectional side view of the reel  110  and rotating reel assembly  100 . 
     The rotating reel assembly  100  consists of the reel  110  rotatably mounted on a frame. The frame in the embodiment described in FIGS. 5 and 6 includes a first end plate  134 , a first static bearing  136 , a second end plate  138 , and a second static bearing  140 . The reel  110  comprises a core  112  interposed between a first flange  122  and a second flange  126 . The core  112  and the flanges  122  and  126  may suitably have the same structure as the core  12  and flanges  22  and  26 , respectively, of FIGS. 1,  2 ,  3  and  4 . 
     The reel  110  further comprises a first hub  130  and a second hub  132 . FIGS. 8A and 8B illustrate first and second perspective views of a hub including a dynamic bearing. Specifically, FIGS. 8A and 8B illustrate the first hub  130  apart from the rotating reel assembly  100 . of FIGS. 5 and 6. The second hub  132  preferably has substantially the same structure as the first hub  130 . 
     Referring to FIGS  6 ,  8   a  and  8   b , the first hub  130  includes a disk-shaped, radially sloped reinforcement portion  150 . The reinforcement portion  150  extends radially adjacent the first flange  122  to provide structural support thereto (see FIG.  6 ). The first hub  130  further includes a substantially cylindrical dynamic bearing  144  that extends axially from and defines an inner radius of reinforcement portion  150 . The dynamic bearing  144  terminates in an inner axial edge  145 . The first hub  130  is preferably constructed of a plastic material. The use of plastic material for the first hub  130  provides for improved reel rotation and still permits the reel  110  to otherwise be constructed predominantly of paper. 
     The first hub  130  further includes a substantially cylindrical locking ring  142  disposed radially outward the dynamic bearing  144  and which extends axially from the reinforcement portion  150 . The locking ring  142  has a radius substantially defined by the inner surface  118  of the core  112 , and includes a plurality of locking ring barbs  146 . As shown in FIG. 6, the each of the plurality of locking ring barbs  146  engage the axially innermost edge of at least one of the first plurality of flexible fingers  124  of the first flange  122 . In a preferred embodiment, each of the plurality of locking ring barbs  146  is wedge-shaped member having a radially inward side flush with the locking ring  142  and a radially outward side defining a protrusion from the locking ring  142 . 
     The plurality of locking ring barbs  146  secure the first hub  130  to the core  112  and/or first flange  122 . The first plurality of flexible fingers  124  are typically secured to the inner surface  118  with an adhesive. The locking ring barbs  146  engagement with the first plurality of flexible fingers  124  within the core  112  inhibit axial motion of the first hub  130  with respect to the first flange  122 . 
     In contrast to the prior art, which relied on either adhesives, radial friction, or a combination thereof to secure a plastic hub to the flange, the reel  110  of the present invention utilizes an axial engagement surface between the barbs  146  and the flexible fingers  124  to secure the first hub  130  to the first flange  122 . In particular, the first flange  122  is securely attached to the inner surface  118  because of the large gluing surface area provided by the first plurality of flexible fingers  124 . That secure attachment allows the axial engagement surface to provide a structurally and mechanically strong axial retention scheme between the first hub  130  and the first flange  122 , particularly for a reel having a plastic hub, a paper core and paper flanges. 
     The first hub  130  further includes a plurality of support ribs  148  that extend from the locking ring  142  to the dynamic bearing  144 . The support ribs  148  provide structural support, which allows for the use of a thinner plastic structure of the first hub  130 , having less mass. 
     Referring again to FIGS. 5 and 6, the reel  110  is rotatably supported by a frame, and specifically, the first and second end plates  134  and  138 , respectively, and the first and second static bearings  136  and  140 , respectively. FIGS. 7A and 7B illustrate first and second perspective views of a static bearing, and particularly, the first static bearing  136  or use in the rotating reel assembly  100  of FIG.  5 . 
     Referring to FIGS. 6,  7 A, and  7 B, the first static bearing  136  includes a disk-shaped bearing flange  154  having an inner radius defined by an axially extending, substantially cylindrical bearing surface  162 . The bearing surface  162  is preferably constructed of plastic. Furthermore, the entire first static bearing  136  is preferably constructed of a single piece of molded plastic. 
     The bearing surface  162  includes a plurality of axial retention barbs  152  disposed on the end of the bearing surface  162  that is axially distant from the bearing flange  154 . The bearing surface  162  has a radius slightly smaller than, and is inserted into, the static bearing  144  (see FIGS.  5  and  6 ). When the rotating reel assembly  100  is fully assembled, an axial retention surface  152   a  on the axial retention barbs  152  engages the static bearing  136  within the core  112  to inhibit axial movement of the static bearing  136  with respect to the dynamic bearing  144  and first hub  130 . While the engagement of the axial retention barbs  152  with the static bearing  144  inhibit axial movement, the dynamic bearing  144  may nevertheless freely rotate with respect to the static bearing  136 . 
     Because rotation of the reel  110  with respect to the frame is an important feature of the rotating reel assembly  100 , it is desirable to reduce the friction between the dynamic bearing  144  and the static bearing  136 . To this end, it may be preferable in some applications to construct the dynamic bearing  144  from a first plastic material and the static bearing  136  from a second plastic material. The use of different plastic materials advantageously reduces the effect of stiction, a phenomenon observed when similar plastics are used in moving parts. Stiction causes moving parts constructed of the same plastic material to require a higher breakaway torque. Accordingly, it may be advantageous to utilize different plastic materials for the dynamic bearing  144  and the top static bearing  136 . For example, the dynamic bearing  144  may suitably be constructed from a styretics-based polymer and the static bearing  136  may suitably be constructed from a polyolefin material. In many embodiments, however, the manufacturing costs associated with use of dissimilar plastics may exceed the benefits in the reduction of stiction. As a result, it is often sufficient to construct the dynamic bearing  144  and the static bearing  136  of similar plastic materials. Those of ordinary skill in the art may readily determine whether the use of dissimilar plastics is appropriate for their specific implementation. 
     The first static bearing  136  further includes a plurality of bearing grips  156 . Each of the plurality of bearing grips is connected at one end to the bearing flange  154  and has a surface spaced apart from and substantially parallel to the bearing flange  154 . The bearing grips  156  and the bearing flange  154  trap portions of the first end plate  134  therebetween, thereby securing the first static bearing  136  to the first end plate  134 . The second static bearing  140  preferably has the same structure as the first static bearing  136 . The bearing flange  154  further includes a plurality of locking fingers  158  disposed opposite one or more of the bearing grips  156  and extending upward from the bearing flange  154  toward the bearing grips  156 . 
     The static bearings  136  and  140  employed by the rotating reel assembly  100  in the above embodiment of the present invention facilitate improved convenience in rotating reel assembly usage. Specifically, in addition to the features discussed above, the axial retention barbs  152  secure the reel  100  to the end plates  134  and  138  without requiring a box or other retaining structure. By contrast, prior art reels are not secured to the end plates until they are loaded into the box. As a result, the loaded and often heavy reel must be careful manipulated onto the assembly and into the box. Specifically, the two end plates or fixtures are required to be held in place when the reel assembly is loaded into a box. According to the present invention, the two end plates  134  and  138  need not be held in place or carefully manipulated because the axial retention barbs  152  provide that structural function. 
     The assembly of the reel  110  is similar to the assembly of the reel  10  of FIGS. 1,  2 , and  3 . In particular, the first flange  122  is first located adjacent to the first end  114  of the core  112 . The first plurality of flexible fingers  124  are then forced axially inward the first end  114  of the core  112 . As before, the first hub  130  is used to force the first plurality of flexible fingers  124  into the core  112 . Specifically, the first hub  130  is positioned atop the first flange  122  such that the locking ring  146  is in registration with the inner surface  118  of the core  112 . The first hub  130  is then forced into the core  112 , which causes the first plurality of flexible fingers  124  to bend and engage the inner surface  118 . 
     Typically, an adhesive is first applied to the inner surface  118  proximate the first end  114  of the core  112  prior to insertion of the first hub  130 . The compression force caused by insertion of the first hub  130  causes migration of the adhesive through and among the first hub  130 , the first plurality of locking fingers  124 , and the core  112 , thereby creating a secure attachment. Alternatively, adhesive may be applied to the locking finger  126 , the first hub  130 , or both. 
     As the first hub  130  is inserted, the locking ring barbs  146  temporarily plastically deform radially inward. Once the first hub  130  is inserted to an axial position in which the locking ring barbs  146  clear the first plurality of fingers  124  within the core  112 , the locking ring barbs  146  snap back to engage the axially inward surface of the first plurality of flexible fingers  124  as shown in FIG.  6 . The first hub  130  may also be treated with an adhesive to secure the first hub  130  to the first plurality of flexible fingers  124 . The second flange  126  and the second hub  132  are secured to the core  112  in substantially the same manner. 
     The frame is also prepared prior to assembly of the finished reel  110  to the frame. Specifically, the first static bearing  136  is secured to the first end plate  134  and the second static bearing  140  is secured to the second end plate  138 . Referring to FIG. 5, the first end plate  134  includes a central opening  164  having an outer perimeter defined by an alternating series of knobs  166  and recesses  168 . During assembly, the bearing grips  156  (see FIG. 7A) are inserted into the recesses  168  until the bearing flange  154  (see FIG. 7A) engages the first end plate  134 . The first static bearing  136  is then rotated until the bearing grips  156  engage the knobs  166 . The bearing grips  156  slightly deform to allow the locking fingers  158  to traverse the knobs  166 . Once the first static bearing  136  is rotated such that the knobs  166  traverse the locking fingers  158 , the bearing grips  156  snap back to cause the locking fingers  158  to engage the knobs  166 . The engagement of the locking fingers  158  and the knobs  166  inhibits back rotation of the first static bearing  136  with respect to the first end plate  134 . The second static bearing  140  is secured to the second end plate in substantially the same manner. 
     The first static bearing  136 , after assembly onto the first end plate  134 , is then inserted into the first dynamic bearing  144 . The first static bearing  136  slightly plastically deforms to allow the axial retention barbs  152  to traverse the first dynamic bearing  144  during insertion. Once the axial retention barbs  152  clear the axially inward edge of the first dynamic bearing  144 , the axial retention barbs snap back to engage the first dynamic bearing  144  to inhibit axial movement. The second static bearing  140  is inserted into the second dynamic  144  in substantially the same manner. 
     It will be understood that the above embodiments and configurations are given by way of example only. Those of ordinary skill in the art may readily devise their own implementations that incorporate the principles of the present invention and fall within the spirit and scope thereof. For example, the axial retention barbs  152  may be replaced by another structure having and axial retention surface to inhibit axial movement of the static bearings with respect to the dynamic bearings.