Abstract:
The present invention comprises a flexible material storage device that may be transported disassembled directly to the end user. The end user may quickly and easily assemble the device, that includes a tube portion and flanges. The device is substantially held together by a unique locking system that includes frictional inducing components and a series of aligned tabs and cut-out portions.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates generally to the field of material storage and particularly to storage devices used for storage and transport of flexible materials.  
         [0003]     2. Description of the Related Art  
         [0004]     Reels and similar devices comprise primarily a spool upon which flexible materials may be wound and stored or transported. The stored material is normally flexible enough to allow it to be wound around the spool. The addition of flanges attached to both ends of the spool prevent the material from falling off the edge of the spool, as well as aiding in winding the material in the most efficient manner possible.  
         [0005]     The need for spools is quite great, and a variety of materials are stored and transported on spools. Cables, ropes, and wire are just a few examples of the materials that benefit from the use of spools and similar storage devices. Currently, reels and spools are completely manufactured by companies that specialize in the manufacture of these devices. These reel producing companies typically manufacture the flanges, the spool or tube portions, and the fasteners that connect the flanges to the spool portion. The reel company also typically provides the labor for assembly, and then ships the completed reel to the end user for their specific application.  
         [0006]     Not surprisingly, reel manufacturing is limited by geographies. Fully constructed reels are extremely bulky, and there is no simple solution for long distance shipping that is cost effective for most businesses. In addition, companies that use reels typically do not assemble their own reels due to the number of variables and components required to manufacture customized reels.  
         [0007]     Various solutions have been introduced attempting to simplify the problems associated with flexible material storage. For example, Weisburn, et al., U.S. Design. Pat. No. D370,908 discloses an ornamental design for a tape reel flange. The drawings appear to illustrate levers along with tabs that include holes, ostensibly to lock the flange to a hub.  
         [0008]     The utility patent granted to Cohen, U.S. Pat. No. 3,239,159 discloses a tape-collecting reel designed to decrease inertia of the device by providing cut outs in the flange portion. The reel is designed to be assembled and disassembled quickly and easily by the removal of flange discs on either end of the reel. The flanges include keyholes that contain enlarged openings at the end of narrow slots. This arrangement allows a locking pin to be inserted, and then locked in place with rotation of the disc flange.  
         [0009]     Posso, U.S. Pat. No. 5,114,089 discloses another tape reel that includes detachable flanges and a means for locking the flanges to the hub. The locking mechanism comprises a series of axially positioned tabs that are placed over locking bars. By rotating the flange, the locking bars engage the tabs thereby locking the flanges in place.  
         [0010]     Witwer, et al., U.S. Pat. No. 5,806,788 discloses a so-called knockdown reel assembly. The term “knockdown” refers to the ability of the reel to be collapsed for easy storage and transport. The device includes a drum and end flanges that combine to form the reel. Additionally, the drum comprises a pair of separate segments that may be releasably locked. The end flanges include an interior disc portion that is attached to the flange. The drum segments then slide over and lock onto this disc portion of the end flanges to provide a locked assembly. The entire device may be made from any suitable lightweight plastic material.  
         [0011]     Vislocky, et al., U.S. Pat. No. 6,045,087 discloses a spool with snap fit flanges. The spool is capable of quick and easy assembly by means of locking tabs that will snap into place when properly aligned and inserted within receiving portions on the hub. The alignment of the flanges with the receiving portions is further simplified by means of a guide comprising a notch in the end of the hub that allows the flange to be inserted in only one position. This alignment tool is designed to take out any guesswork that might be involved with attaching the flange to the hub.  
         [0012]     Häfner, U.S. Pat. No. 6,089,500 discloses a collapsible spool that includes what are termed bayonet couplings. The couplings allow for easy assembly of the flanges to the hubs simply by placing the flange on the hub, and rotating to a locked position. Additional stability can be achieved by inserting locking plugs into holes that will be available only when the flange is properly aligned with the hub in a locked position.  
         [0013]     Charlton, U.S. Patent Application Publication No. 2002/0053625 discloses a demountable cable reel that is also designed to provide quick and easy assembly and disassembly without having to remove the cable from the hub. This feature is particularly useful in the event that one of the flanges becomes damaged and must be replaced. The locking mechanism that this device employs is a fairly straightforward gear tooth style configuration. The portion resembling a gear is attached to the flange and inserted within a mirror-image style cut out of the gear. By rotating the flange, the extensions of the gear shaped element are thereby locked into position relative to the hub. A locking pin may also be employed for additional stability.  
         [0014]     Although these prior art inventions may have adequately met their desired applications, none of them include the unique structure of the present invention, or its inherent benefits.  
         [0015]     Therefore, what is required is a flexible material storage device that can be assembled quickly and easily by the end user.  
         [0016]     What is further required is a flexible material storage device that may be transported in bulk in the most efficient manner.  
         [0017]     What is also required is a flexible material storage device that utilizes a unique locking arrangement that allows for quick assembly, and a strong and stable structure.  
       BRIEF SUMMARY OF THE INVENTION  
       [0018]     Accordingly, what is provided is a flexible material storage device of the present invention that can be quickly and easily produced in a cost-effective manner.  
         [0019]     What is also provided is a flexible material storage device of the present invention that can be shipped in greater quantities than devices known presently.  
         [0020]     What is further provided is a flexible material storage device of the present invention that can be stored in bulk by the end user in the most efficient manner.  
         [0021]     What is also provided is a flexible material storage device of the present invention that requires minimal labor to assemble and put the device into use.  
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0022]     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings where:  
         [0023]      FIG. 1  is a perspective view of a tube portion of the present invention.  
         [0024]      FIG. 2  is an interior view of a tube portion of the present invention.  
         [0025]      FIG. 3  is a top view of a tube portion of the present invention.  
         [0026]      FIG. 4  is a side view of a tube portion of the present invention.  
         [0027]      FIG. 5  is an exterior view of a tube portion of the present invention.  
         [0028]      FIG. 6  is a perspective view of the present invention prior to rotation and locking.  
         [0029]      FIG. 7  is a top view of the present invention in a rotated and locked position.  
         [0030]      FIG. 8  is a perspective view of the flange base of the present invention.  
         [0031]      FIG. 9  is a top view of a flange. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]      FIG. 6  illustrates a perspective view of the flexible material storage device  1  of the present invention. Those skilled in the art will readily recognize that although the invention is termed a “storage” device, the device can also be used for transport of materials, as well as various operative procedures linked with the paying out and retrieval of flexible materials. The flexible materials contemplated for use with the present invention include any type of material that can be wound around the tube  2  of the device. The list may include, but is not limited to, rope, wire, all manner of cable, and any type of material, whether in tube, sheet or other form, that lends itself to being wound upon a reel-type device.  
         [0033]      FIG. 6  illustrates the present invention in a semi-assembled state, just prior to rotation of first flange  10  and second flange  11 . The present invention may include a tube  2 , which in turn may comprise a first tube portion  3 , and a second tube portion  4 . The tube also includes a first end and a second end from which first end tabs  5  and second end tabs  6  extend. A first flange  10  and second flange  11  are also shown, with first end tabs  5  and second end tabs  6  protruding through first end flange cut-outs  12 , and second end flange cut-outs  15 .  
         [0034]      FIG. 1  illustrates first tube portion  3 . First end tabs  5  are displayed on first end  18 , and second end tabs  6  are shown along second end  20 . The end tabs  5  and  6  may include a beveled portion to easy the assembly process. The end tabs may also include first end tab locks  23  and second end tab locks  24  that may be beveled to further ease the assembly process. Also shown are first end detents  19 , and second end detents  25 . The first and second end detents may be located on the peripheral edge of an arm  50  and  51  respectively. The arms  50  and  51  may be resilient, allowing the appropriate amount of flexibility to provide for easy assembly, but then maintaining an appropriate amount of friction to aid in the stability of the assembled device. First pin edge  21  is illustrated opposite to first receptacle edge  22 . The tube portions may include a smooth or rough outer surface, and may include variable inner surface structures to enhance support and strength of the tube. In  FIG. 2 , it will be seen that the inner surface of the tube portion includes rib structures to enhance the strength of the tube. Various truss structures could also be used within the tube without departing from the scope of the present invention. Although first tube portion  3  has been shown, it will be clear to those skilled in the art that second tube portion  4  is basically a mirror image of first tube portion  3 . In practice, first pin edge  21  of the first tube portion  1  will meet and connect with second receptacle edge of second tube portion  4 . Likewise, first receptacle edge  22  of first tube portion  3  will mate with second pin edge of second tube portion  4 .  
         [0035]      FIG. 3  is a top view of second tube portion  4 , displaying second end tabs  6  and second end detents  25 . In a preferred embodiment each tube portion  3  and  4  would include a pair of end tabs  5  and  6 , and a pair of corresponding end detents  19  and  25 . The exact number of end tabs and detents may vary depending upon the application, and/or diameter of any portions of the device. Second receptacle edge  26  and second receptacle edge  27  are also shown.  
         [0036]      FIG. 9  details first flange  10 , but those skilled in the art will recognize that second flange  11  will normally mirror the pertinent features, thus the same explanation will apply to both first flange  10  and second flange  11 . First end flange cut-outs  12  are shown along with first end flange lock receptacles  13 . Also shown are first turning receptacles  14 . There may also be a center cut-out to allow the device to be placed upon a spindle and more easily wound and unwound.  
         [0037]     In operation, the first tube portion  3  and second tube portion  4  are connected via their respective pin and receptacle edges. A first flange  10  may be placed atop the tube  2  and the first end tabs  5  aligned with first end flange cut-outs  12 . The first flange may then be rotated in the direction allowed by the first flange cut-outs  12 . As the first flange  10  is rotated, first end detent lock  19  applies upward force upon the first flange  10 . The first end tab lock  23  then engages with first end flange lock receptacle  13 . The first flange  10  is then effectively locked in place based on the locking aspects of the first end tab locks and the frictional force provided by first end detent lock  19 . The second flange  11  may then be connected to the tube  2  in similar fashion.  
         [0038]     In another embodiment, a flange base  30  including support rounds  31  may be utilized to hold the first flange  10  in place. Tube  2  may then be pressed downward and turned to lock the first flange  10  in place. After the tube  2  and second flange  11  are positioned and aligned, the procedure may be repeated in the opposite direction.  
         [0039]     The ease with which the present invention may be constructed should now be readily apparent. Many such devices may be shipped, disassembled in bulk to the end user. The device may then be easily and efficiently stored as desired, or put immediately into service with minimal labor. Cost will further be reduced because a larger number of disassembled devices may be shipped then assembled reel devices produced by other manufacturers. The size, both diameter and length of the device may be varied depending upon the application. In addition, a variety of materials may be utilized, including plastic molds for the tube portions, and flanges comprised of wood materials.  
         [0040]     Although the present invention has been described with reference to particular embodiments, it will be apparent to those skilled in the art that variations and modifications can be substituted therefore without departing from the principles and spirit of the invention.