Abstract:
A flange for a reel for supporting a wound flexible medium includes a plate member and a set of support elements. The reel includes an elongate core defining a longitudinal core axis. The plate member engages the core and extends radially from the core toward an outer edge and has an axially inclined media engaging surface. The set of support elements have a height extending from the plate member in the axial direction, and a length extending radially, at least a first support element extending radially from proximate the core to proximate the outer edge. The axial distance between the plate member and a top of the first support element proximate the outer edge is less than an axial distance between the plate member and the top of the first support element proximate the core.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/409,392 filed Nov. 2, 2010, which is incorporated herein by reference. 
     FIELD OF THE INVENTION 
     The present invention relates generally to reels for supporting wound flexible media such as cable, wire, hose, rope and the like. 
     BACKGROUND OF THE INVENTION 
     Reels for supporting wound flexible media are employed to both store and facilitate the dispensing of wound media such as rope, wire, chain, and strings of parts. The essential elements of a reel include its core, around which the flexible medium is wound, and its flanges, which prevent the wound flexible medium from migrating axially off of the core. Reels intended for industrial use can vary greatly in size. 
     Well-designed reels must combine a high strength-to-weight ratio with low manufacturing cost. One reel design that has gained popularity is a reel in which the core is constructed of either a pressed paperboard material or extruded plastic, and in which the flanges are constructed of a composite or plastic material. The use of paper and plastic components, in general, provides a high strength-to-weight ratio and facilitates the use of relatively straightforward and relatively inexpensive manufacturing techniques. Another lightweight reel design consists of a pressed paperboard core and corrugated paper flanges. While such all-paper reels provide significant economy and light weight, all-paper reels are generally not suitable for certain medium to heavy duty applications because the paper flanges do not have the strength of plastic, wood, or steel flanges. Accordingly, for medium to heavy duty reel applications, plastic or composite flanges provide an advantageous combination of manufacturability, light weight, and strength. 
     Reels having composite or plastic flanges are relatively simple to manufacture. The flanges may be formed using known injection molding techniques. The flanges are then attached to the core to form a reel. 
     During use, reels are subject to many extraneous forces which can possibly damage the reels. For instance, a user may grip the reel by one of its flanges and lift the reel off of the floor. If the reel is not carrying any wound media, the reel is less susceptible to damage from such lifting. On the other hand, if the reel is loaded with a heavy metal wound medium, then the weight of the loaded reel can cause the gripped flange to bend and/or warp when the reel is lifted by the flange. In order to avoid damage caused by such lifting, the typical flange is designed with wall thicknesses that are sufficient to provide the necessary strength and structural integrity. Of course, with increased wall thicknesses also comes increased material costs and weight, neither of which is desirable. 
     Another way in which a reel may be damaged is if an extraneous force is exerted on a flange, such as if the reel is dropped. Such a force exerted on a flange will usually damage the pressed cardboard core. Particularly subject to damage are the ends of the core that engage the flanges. It has been found that an end of a core tends to tear or buckle inwardly when a sufficient force is exerted on the corresponding flange. 
     What is needed, therefore, is a reel that is less subject to damage from extraneous forces and yet does not require an increased amount of material. 
     SUMMARY 
     The invention described herein comprises a reel having a base plate, a core retaining area, and an outer edge defined on the base plate. An inner surface of the base plate extends in a non-planer manner in the radial direction from the core retaining area to the outer edge. In particular, the inner surface of the base plate inclines axially and radially outward from the core retaining area. 
     In one embodiment, a flange for use in a reel for supporting a wound flexible medium includes a plate member and a set of support elements. The reel includes an elongate core defining a longitudinal core axis. The plate member is configured to engage the core and extends radially from the core toward an outer edge and having an axially inclined media engaging surface that extends in a first axial direction as the plate member extends radially outward. The set of support elements have a height extending from the plate member in the first axial direction, and a length extending radially along at least a portion of the plate member, at least a first support element extending radially from proximate the core to proximate the outer edge. The axial distance between the plate member and a top of the first support element proximate the outer edge is less than an axial distance between the plate member and the top of the first support element proximate the core. 
     The above described features and advantages, 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  shows a perspective view of an exemplary embodiment of a reel according to the present invention; 
         FIG. 2  shows a perspective view of a first side of one of the flanges of  FIG. 1 ; 
         FIG. 3  shows a perspective view of a second side of the flange of  FIG. 2 ; 
         FIG. 4  shows a cutaway side view of the flange of  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a perspective view of one embodiment of a reel  10  according to the present invention which includes a core  12 , a first flange  14  and a second flange  15 . As shown in  FIG. 2 , the core  12  defines an axis  13  and has two opposite ends  16   a ,  16   b . When the terms “axial”, “radial” or “circumferential” are used herein, it will mean with respect to the axis  13  such that a line or component that is normal to the axis  13  is referred to as “radial”, and a line or component that is parallel to the axis  13  is referred to as “axial”. A component that extends in an arc or circle at a constant distance from the axis  13  is referred to as “circumferential”. A structure that is referred to as extending in an “axial”, “radial” or “circumferential” way does not mean that such structure extends exclusively in such a manner, unless stated otherwise, but rather that some non-trivial aspect of the structure extends in a way that includes the stated directional component. It will also be appreciated that any structure described as annular does not necessarily form an uninterrupted annular structure, but rather a structure that is predominantly annular despite one or more interruptions in the annular continuity. 
     Referring again to the reel  10 , the core  12  typically, but not necessarily, has a substantially circular, uniform, cross-sectional shape along its axial length (parallel to axis  13 ) such that the core  12  assumes the configuration of a hollow cylinder. In the exemplary embodiment described herein, the core  12  can comprise a pressed paperboard tube. In another example, the core  12  can comprise an extruded plastic tube. 
     The flanges  14 ,  15  are preferably molded of a plastic or composite material. However, metal and other rigid materials may be used while still retaining many of the advantages of the present invention. 
       FIGS. 2 and 3  show perspective views of first and second sides  14   a ,  14   b , respectively, of the flange  14 .  FIG. 4  shows a cutaway side view of the flange  14 . With reference to  FIGS. 1 ,  2  and  3 , the flange  14  is in the general form of an annulus  18  having first and second sides  18   a ,  18   b , respectively. The annulus  18  includes a core plate  24  and plate member  19 . The annulus  18  also includes a number of surface and structural features formed on the core plate  24  and plate member  19 , which are discussed herebelow. 
     In general, with reference to  FIGS. 1 and 3 , the core plate  24  is in the form of a small annulus that extends radially from an inner edge  21  to a core edge  32 . The core edge  32  has a circumference that corresponds to the circumference of the core  12 . As shown in  FIGS. 1 and 3 , an annular core edge wall  34  extends axially inward (in the direction  25  of  FIG. 1 ) from the core plate  24  at the core edge  32 . A second annular core wall  36  also extends axially from the core plate  24  and is disposed concentrically inward of the core edge wall  34 , such that the annular core edge wall  34  and the second annular core wall  36  form an annular channel  38  for receiving an edge, not shown, of the core  12 . 
     The base plate  19  includes a first surface  19   a  (see  FIGS. 1 and 2 ) and an opposite second surface  19   b  (see  FIG. 3 ), and extends radially outward from the core edge  32  to an outer edge  23 . The second surface  19   b  faces axially inward on the reel  10 , and forms a surface that engages and supports any wound media (e.g. cable, rope, wire), not shown, wound on the core  12  during normal use. 
     In the embodiments described herein, at least the second (media engaging) surface  19   b  of the base plate  19  is flared or inclined such that it also extends axially outward as it extends radially outward. In this embodiment, entire plate member  19 , including both the first surface  19   a  and the second surface  19   b , include the axially outward flare. The angle of flare (axial component versus radial component) is slight, typically less than 10°. Moreover, in the embodiment described herein, the angle of axial inclination of the plate member  19  decreases as a function of radial distance from the core  12 , such that the second surface  19   b  appears slightly concave. (See, e.g.,  FIG. 4 ) In an alternative version of the flange  14 , the angle of axial inclination of the plate member  19  remains substantially constant. 
     Referring to  FIG. 3 , the plate member  19  includes a plurality of voids  42  formed as a set of circumferentially dispersed, radially extending voids  42 . Each of the voids  42  is covered by a corresponding raised wall  44  that is axially displaced from the plate member  19 . As shown in  FIGS. 1 and 2  as well as  FIG. 3 , a set of substantially axially extending connecting walls  46  interconnects each of the raised walls  44  to the plate member  19 . 
     As shown in  FIGS. 1-3 , an axial distance between the plate member  19  and the raised walls  44  proximate the outer edge  23  is less than an axial distance between the plate member  19  and the raised walls  44  proximate the core  12  or core plate  24 . Moreover, the axial distance between the raised walls  44  and the plate member  19  decreases as a function of radial distance from the core  12  or core plate  24 . In the embodiment described herein, the decrease in axial distance is a result of the axial inclination of the plate member  19  discussed further above, as well as an axial inclination in the opposite direction of the raised walls  44 . In alternative embodiments, the raised walls  44  may suitably extend without appreciable axial inclination. 
     Accordingly, one feature of the above-described design is that the decreasing axial difference between the raised walls  44  and the plate member  19  creates more flexibility at the radially outward portions of the flange  14  and greater stiffness at the radially inward portions of the flange  14 . As a consequence, the flange  14  is able to withstand shock delivered to the edge  23  (as by dropping, for example) in a more advantageous manner. Specifically, the gradual decrease in flexibility radially inward on the flange  14  creates a shock absorption phenomenon that improves flange durability. The gradual decrease in flexibility furthermore creates a failure mechanism that resists cracking at or near the core  12  of the reel  10 , which is preferable to failure that extends all of the way to the core  12 . 
     The flange  14  includes additional strengthening features in the form of an outer rim  22 , radial ridges  48 , an inner rim  50  on the first side  14   a , and radial ridges  52  and circumferential ridges  54  on the second side  14   b . The flange  14  further includes a series of circumferentially spaced, circular voids  56  surrounded by perimeter ridges  58 . 
     The outer rim  22  is substantially circular in shape and extends axially in the direction  29  from the first side  19   a  of the plate member  19 . The outer rim  22  is disposed in proximity to the outer edge  23 . The inner rim  50  is also substantially circular in shape and extends axially in the direction  29  from the first side  19   a  of the plate member  19 . The inner rim  50  is disposed concentrically approximately half way between the core edge  32  and the outer edge  23 . 
     The radial ridges  48  are circumferentially dispersed throughout the first side  14   a  of the flange  14 , and comprise ridges or ribs having a length that extend in the radial direction with respect to the core  12 , and a height that extends primarily in the axial direction  29  from the first surface  19   a  of the plate member  19 . To the extent that one or more of the radial ridges  48  correspond in location to the raised walls  44 , the corresponding radial ridge  48  extend from the raised wall  44  in the axial direction  29 . The radial ridges  48  have an axial height that remains substantially constant. The radial ridges  48  may suitably extend in length from the core edge wall  34  to the outer rim  22 . 
     In the embodiment described herein, the circular voids  56  are relatively small in diameter, being at least an order of magnitude smaller than the diameter of the flange  14 . The circular voids  56  are disposed such that they intersect with each of the raised walls  44  and the outer rim  22 . The raised perimeters  58  extend from the surface  19   a  of the plate member in the axial direction  29 , such that the raised perimeters  58 , the radial ridges  48  and the rims  22 ,  50  all extend to substantially the same height. The circular voids  56  and corresponding raised perimeters  58  provide additional deflection of fracture lines in the flange  14  from the outer edge  23  to the core edge wall  34 . 
     Referring now to  FIG. 3 , the second side  18   b  of the annulus  18  further includes radial ridges  52  and circumferential ridges  54  that extend in the second axial direction  25  from the underside of the raised walls  44 . In particular, in this embodiment, a radial ridge  52  having a radial length between the core edge wall  34  and proximate the outer edge  23 , and specifically, the perimeter ridge  58  of the corresponding circular void  56 . The circumferential ridges  54  have a circumferential length that spans circumferential width of the corresponding raised walls  44 . The circumferential ridges  54  may suitably align with the inner rim  50  of the first side  18   a  of the annulus  18 . The ridges  52 ,  54  in this embodiment provide improved strength. 
     Referring back to  FIG. 1 , the second flange  15  preferably has the same shape and structure as the first flange  14 . 
     During assembly, the core  12  is inserted into the annular channel  38  and secured therein by fasteners, adhesive, or spin welding. For example, the core  12  may be secured to the flanges  14 ,  15  by use of staples. More particularly, staples, not shown, may be driven through the core edge wall  34  into the core  12 . Similarly, staples can be driven through the second annular core wall  36  and the core  12 . 
     In another embodiment, the flanges  14 ,  15  can be attached together by bolts (not shown), thereby securely retaining the core  12  between the flanges  14 ,  15 . The bolts can be inserted through the countersunk bolt holes, not shown, formed in the flange  14  and into correspondingly aligned bolt holes in the flange  15 . The ends of the bolts that are opposite the heads of the bolts can be threaded so that the bolts become threadedly coupled to the flange  15 . 
     The use of bolts and staples as securing means allows for the core  12  to be constructed of paper or plastic. Similarly, the use of an adhesive between the core  12  and the flanges  14 ,  15  allows for the core to be constructed of different materials. In another embodiment, the core  12  is formed of plastic suitable for spin welding the core  12  to the flanges  14 ,  15 . Such techniques are conventional, and disclosed, for example, in U.S. Pat. No. 7,534,316, which is incorporated herein by reference. 
     It will be appreciated that many modifications may be made to the disclosed embodiments and nevertheless obtain the advantages of the tapered or flared media engaging surface of the annulus. For example, although the inner and outer rims  50 ,  22  are substantially circular, it will be appreciated that the exact shapes of the rims can be varied depending on the requirements of the application for the reel  10 . It will further be appreciated that although the raised wall  44  and corresponding connecting walls  46  form a support structure that is generally U-shaped in cross section, those structures may be replaced by ridges or ribs having a different cross section, such as a V-shaped cross section, or even a single beam or rib. In the latter two embodiments, no flat raised wall is employed. 
     It will be appreciated that 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 number, heights and orientations of the various support ridges, the spacing therebetween, and the patterns formed thereby can all readily be modified without departing from the spirit and scope of the invention. Likewise, the number, heights and orientations of the inner support ridges  40 , the spacing therebetween, and the patterns formed thereby can also all readily be modified without departing from the spirit and scope of the invention. Moreover, the heights and spacing between the radially inner wall  30  and the radially outer wall  32  can be modified within the spirit and scope of the invention.