Abstract:
An industrial reel wrap is designed for wrapping an industrial reel having a central spool and a pair of end plates connected thereto. The reel wrap includes a central portion that is spannable across a distance between the end plates of the reel. The reel wrap additionally includes first and second side portions that are coupled to the central portion. The first and second side portions each include a number of tabs along the length of the reel wrap. The tabs are securable to the exterior surface of each the end plates, the first and last of the tabs are preferably overlapped to completely enclose the industrial reel. The tabs are separated from the central portion by a double crease seam to enable easier folding of the tabs. The reel wrap may be scored to enable compact folding for shipment.

Description:
RELATED APPLICATIONS 
     The present application is a continuation in part claims priority to U.S. patent application Ser. No. 09/894,461, filed Jun. 28, 2001, now abandoned, which claims priority to U.S. Provisional Application No. 60/214,998 filed Jun. 29, 2000. Each of the identified patent applications is hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the protection of materials stored on an industrial reel and, more particularly, to a corrugated wrap that is used to wrap the circumference of an industrial reel thereby providing protection to the materials stored thereon. 
     BACKGROUND OF THE INVENTION 
     Traditionally, wooden spools or industrial reels that are used to transport, store, and dispense various materials, e.g., fiber optics, other types of transmission cables, wires, etc., have had their contents protected through use of wood lagging strips, as shown in the prior art of FIG.  1 . 
     Referring to FIG. 1, the traditional, prior art manner of preparing an industrial reel  10  for shipping through the use of wood lagging  12  is shown. Industrial reel  10  is generally fabricated from wood and includes a central spool  14  and a pair of end plates  16 . Various types of wire and/or cable  18  are wrapped about the central spool  14  and maintained thereon by virtue of end plates  16  allowing industrial reel  10  to operate as a shipment, storage and dispensement container all in one. To prepare industrial reel  10  for shipment, wood lags (lagging strips)  12  are placed one-by-one around the circumference of industrial reel  10 , requiring significant preparation time. Each wood lag  12  is secured at each end by a nail  19  to one of end plates  16 . The nail is directed into the width  20  of each of end plates  16  rather than the interior face  22  or exterior face  23  of end plates  16 . As such, a nail directed at an angle presents the possibility of extending through the interior face  22  of end plate  16 , resulting in an unreliable wood lag and the possibility of damaging the contents of industrial reel  10 . 
     Each of the lagging strips  12  has been cut to the width of the industrial reel and secured to end plates through the use of nails and a nail gun. The wood lagging  12  presents gaps between individual lagging strips through which foreign material may reach the industrial reel contents. The securing and subsequent removal of the lagging strips  12  from the industrial reel  10  adds significant time, and resultant costs, to the industrial reel shipping process. The use of nails and a powered nail gun provides the possibility of injury to the individual preparing the shipment and, as well, the possibility of injury to the spool contents through virtue of a misdirected, long-shanked nail. Additionally, the wood lagging  12  itself adds significant cost to the shipping due to the weight the lagging adds to the industrial reel and its contents. Further, the disposal and/or re-use of the wood lagging  12  is not easily facilitated and also presents a significant recycling concern. Similar problems are presented by plywood and Masonite® lagging when used in place of the wood lagging  12 . 
     In an effort to address at least some of the problems described above, one manufacturer has produced an alternative to wood lagging  12 . Specifically, the alternative is a triple-layered material, i.e., an inner layer of polypropylene foam cushioning, a middle layer of recycled polypropylene, and an outer layer of spunbonded polypropylene. The inner layer is placed in direct contact with contents of the industrial reel and is wrapped directly about the contents rather than about the circumference of the reel end plates, as shown in the prior art of FIG.  2 . The material is secured against the contents of the industrial reel through use of metal banding strips, leaving the end plates exposed. 
     Referring to FIG. 2, the prior art alternative to the configuration of FIG. 1 is shown. In the prior art embodiment of FIG. 2, a triple-layered material  24 , i.e., an inner layer of polypropylene foam cushioning, a middle layer of recycled polypropylene, and an outer layer of spunbonded polypropylene, is wrapped about the contents of industrial reel  10  and is positioned within the diameter of end plates  16 . Material  24  is held in position, i.e., in direct contact with the contents of industrial reel  10 , through use of one or more metal banding strips  26 . As a result of this direct contact, possible damage to the contents of industrial reel  10  is increased according to the pressure applied by metal banding strips  26  upon the contents. Note that because the contents of the industrial reel is most often spooled in a manner wherein the exterior of the contents is visible as a coursed configuration, i.e., the contents is in a side-to-side/top-to-bottom layer configuration as opposed to a layer-beneath-layer configuration as in adhesive tape, many portions of the contents are exposed for potential damage from the elements or reel-to-reel contact. 
     The alternative described above with reference to FIG. 2 does significantly reduce the time needed to wrap and unwrap the industrial reel, it does reduce the overall weight of the industrial reel, and it does eliminate the need for nails and the possible injury they may cause. However, it introduces new problems that were not present with wood lagging. Because the material  24  of the alternative approach is in direct contact with the contents of the industrial reel  10 , there is the possibility that the pattern of the material  24  will be imprinted on the contents of the industrial reel  10 . Further, because this alternative approach wraps the contents of the industrial reel  10  rather than the circumference of the end plates of the industrial reel  10 , there is a possibility that the exposed end plate  16  of an industrial reel  10  will roll into the contents of another industrial reel  10 , thereby damaging its contents. 
     As such, there is a need in the art for a product that addresses the problems presented by wood, plywood, and Masonite® lagging as well as the problems presented by the above-described alternative approach. 
     SUMMARY OF THE INVENTION 
     The needs described above are in large measure met by the industrial corrugated reel wrap of the present invention. The industrial reel wrap is designed for wrapping an industrial reel having a central spool and a pair of end plates connected thereto. The industrial reel contains spooled contents that are generally wound so that a plurality of courses exists between the first and second end plates. The industrial reel wrap includes a central portion that is spannable across a distance between the end plates of the industrial reel. The industrial reel wrap additionally includes first and second side portions that are coupled to the central portion. The first and second side portions each include a number of tabs along the length of the industrial reel wrap. The tabs are securable to the exterior surface of each the end plates. 
     In one embodiment of the invention the industrial reel wrap is preferably provided with sufficient length so that it may continuously surround the exterior circumference of the industrial reel, spanning the distance between end plates, and so that the last tab secured to the industrial reel overlaps the first tab secured to the industrial reel to ensure a complete enclosure thereof. The tabs may be place in a side-by-side or gapped arrangement. 
     In another embodiment of the invention, the central portion of the industrial reel wrap is unitary with the first and second side portions of the industrial reel wrap, with the side portions being separated from the central portion by a formed double crease. The double crease is preferably used when the industrial reel wrap is of a corrugated material and the flutes of corrugation are oriented opposite to the length of the reel wrap, i.e., the flutes extend from end plate to end plate rather than about the circumference of the industrial reel. 
     In still another embodiment of the invention, at least the central portion is provided with one or more scores enabling the industrial reel wrap itself to be folded to a more compact shape for shipment purposes. Bi-fold or tri-fold configurations are two options for a folding scheme of the industrial reel wrap. In the instance of the industrial reel wrap being made from a double-faced corrugated material, the score line is preferably only made through one face of the double-faced corrugated material leaving the underlying corrugated and second face intact. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a prior art configuration of an industrial reel, the contents of which have been protected through the use of wood lagging about the circumference of the industrial reel; 
     FIG. 2 is a prior art configuration of an industrial reel, the contents of which have been protected through the use of a wrap that is wrapped about and in direct contact with the contents of the industrial reel; 
     FIG. 3 depicts an industrial reel, the contents of which have been protected through the use of an industrial corrugated reel wrap of the present invention; 
     FIG. 4 depicts a corrugated material that may be used in the industrial corrugated reel wrap of the present invention; 
     FIG. 5 depicts an alternative corrugated material that may be used in the industrial corrugated reel wrap of the present invention; 
     FIG. 6 depicts one pattern, having closely spaced tabs, for the industrial corrugated reel wrap of the present invention; 
     FIG. 7 depicts an alternative pattern, having set-apart tabs, for the industrial corrugated reel wrap of the present invention; 
     FIG. 8 depicts the industrial corrugated reel wrap, with the pattern of FIG. 7, wrapped partially about an industrial reel; 
     FIG. 9 depicts the industrial corrugated reel wrap of the present invention being applied to an industrial reel through use of a pneumatic fastening tool; 
     FIG. 10 depicts an industrial reel wrapped by the industrial corrugated reel wrap of the present invention wherein the end of the wrap is completed by topping the first tab with the last tab; 
     FIG. 11A depicts a single crease configuration that may be provided between the center and side portions of the industrial reel wrap; 
     FIG. 11B depicts a double crease configuration that may be provided between the center and side portions of the industrial reel wrap; 
     FIG. 12 depicts the industrial corrugated reel wrap having been scored to enable folding for shipping purposes; and 
     FIG. 13 depicts a plurality of industrial corrugated reel wraps that have been folded and stacked atop each other for shipping. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     An industrial, corrugated reel wrap of the present invention is shown generally at  50  in the figures and is used to protect and shield the contents of an industrial reel  10 . The corrugated reel wrap  50  provides for fast installation and removal, significantly reduces the amount of weight added to the industrial reel compared to wood lagging, and reduces the possibility of injury to the shipper and/or contents of the industrial reel. 
     The industrial, corrugated reel wrap  50  of the present invention is shown in FIGS. 3-5. As FIG. 3 depicts, industrial, corrugated reel wrap  50  is designed to span the overall width of industrial reel  10  and to be secured to the exterior of industrial reel  10  by staples  51 , thereby avoiding the problems associated with nailing wood lagging to the end plates. Staples  51  are selected with a length that is insufficient to penetrate the end plate  16 , thereby protecting the contents of the industrial reel  10  from damage. Referring to FIGS. 3 and 6, industrial, corrugated reel wrap  50  incorporates a central portion  56 , which is of sufficient width to extend between end plates  16  of industrial reel  10 , and two side portions  58  that are preferably unitary with central portion  56 , being joined at a respective side margin of the central portion  56 . Each of side portions  58  includes a plurality of tabs  60  that have been preferably die-cut to include angled sides  62  that extend into an arc portion  64  that is common with the angled side  62  of the next proximate tab  60 . Industrial, corrugated reel wrap  50  may be of any desired length and width that is suitable to a specific application. 
     As FIG. 4 depicts, industrial, corrugated reel wrap  50  is not a wood product but rather is a multi-layered material manufactured from high-density polyethylene (HDPE), i.e., a plastic, having a basis weight of 300 to 500 lbs. Of course, other plastics or plasticized materials, e.g., plastic coated fiberboard, may be used without departing from the spirit or scope of the invention. HDPE is used to create an industrial, corrugated reel wrap  50  that preferably incorporates two outside liners  52  and a fluted center  54 , as shown in FIG.  4 . Alternatively, industrial, corrugated reel wrap  50  may include only a single outside liner  52  in combination with fluted center  54 , as shown in FIG.  5 . The flutes  55  of fluted center  54  may extend along the length or along the width of industrial, corrugated reel wrap  50 . Industrial, corrugated reel wrap  50  may be manufactured through lamination, extrusion, or other like processes. 
     Because industrial, corrugated reel wrap  50  is manufactured from HDPE it is 100% recyclable, thus eliminating the element of waste product that results from wood lagging. Further, because industrial, corrugated reel wrap  50  is manufactured from HDPE, it may be customized with minimal investment and can be made available in a wide range of colors, including translucents. The HDPE material also means that industrial, corrugated reel wrap  50  is unaffected by water, is stronger and more durable than corrugated fiberboard, is extremely lightweight, will not rust, rot, mildew or corrode like metal or wood, and will resist a wide range of chemicals, grease and dirt. The HDPE material allows industrial, corrugated reel wrap  50  to be easily and clearly printed upon, and to be tear, puncture, and impact-resistant for protection of the contents of industrial reel  10 . The HDPE material also allows for industrial, corrugated reel wrap  50  to be made anti-static, non-conductive, ultra-violet inhibiting, flame retardant, corrosion retardant, and/or non-skid if desired. Additionally, industrial, corrugated reel wrap  50  may be made with FDA approved resins. 
     FIGS. 7 and 8 depict industrial, corrugated reel wrap  50  incorporating an alternative tab pattern to that presented in FIGS. 3 and 6; of course, numerous other patterns may be used for corrugated reel wrap  50  without departing from the spirit or scope of the invention. The alternative pattern finds industrial, corrugated reel wrap  50  having a central portion  56 , which is of sufficient width to extend between end plates  16  of reel  10 , and two side portions  58  that are preferably unitary with central portion  56 . Each of side portions  58  includes a plurality of tabs  60  that have been preferably die-cut to include angled sides  62 . However, different from the pattern described in the paragraph above, tabs  60  are separated by an elongate space  63 , i.e., gapped, that is substantially equivalent in width to that of one of tabs  60 . 
     FIG. 9 depicts the application of industrial, corrugated reel wrap  50  to an industrial reel  10 . As shown, industrial, corrugated reel wrap  50  is positioned such that central portion  56  extends between end plates  16  of reel  10 , allowing tabs  60  to protrude outward. To secure tabs  60  to industrial reel  10 , they are manually bent downward and fastened, preferably through use of a pneumatic fastening tool  66  (e.g., stapler, nail gun, etc.) to exterior face  23  of end plate  16 , causing central portion  56  to smoothly lie along the edges of end plates  16 . Arc portion  64  and spacing between tabs  60  allow each tab  60  to be bent individually without stress on proximate tabs  60  and to lie flat against end plate  16  without causing gaps between end plates  16  and central portion  56 . Only one fastener  68  (including, for example, staple  51 ) is needed per tab  60  to secure it to industrial reel  10 . Fasteners  68  are selected to have a shank length such that each of fasteners  68  does not penetrate end plate  16  and protrude through interior face  22  upon being secured to end plate  16 . The process of bending and fastening is repeated for each tab  60  through the rolling of industrial reel  10  until all tabs  60  are secured and the area intermediate end plates  16  of industrial reel  10  is enclosed. 
     Completing the enclosure of the area intermediate end plates  16  may be achieved by overlapping the ends of industrial, corrugated reel wrap  50 . Using this manner of completing the enclosure allows for industrial, corrugated reel wrap  50  to be dispensed and cut to a desired length for application to industrial reel  10 . In a preferred embodiment of the invention, the industrial, corrugated reel wrap  50  is manufactured such that an overlap in the ends of the wrap  50  also results in an overlap of tabs  60 , i.e., at least a portion of the very last tab  60   a  on industrial, corrugated reel wrap  50  is secured atop the very first tab  60   b  of industrial, corrugated reel wrap  50 , see FIG.  10 . The overlap of first  60   b  and last  60   a  tabs  60  helps to ensure that industrial, corrugated reel wrap  50  does not separate keeping the contents of the industrial reel  10  always enclosed. In addition to or alternatively, industrial, corrugated reel wrap  50  may be manufactured to a specific length where the ends overlap to complete the enclosure. Within these alternatives, if desired, the ends of industrial, corrugated reel wrap  50  may be provided with an interlocking notch  70  and tab  72  combination to complete the enclosure of wrap  50 , as shown in FIGS. 3 and 9. 
     In a preferred embodiment of industrial, corrugated reel wrap  50 , side portions  58  are unitarily joined to central portion  56  via a single seam crease  72 , see FIG. 11A and, even more preferably, through a double seam crease  74 , see FIG.  11 B. The single seam crease  72  is more appropriately used when the direction of corrugation of the flutes  55  of the industrial reel wrap  50  extend through the length of the industrial reel wrap  50 ; the direction of corrugation is in the same direction as the seam crease  72  making the bending or folding of the tabs  60  at the crease an easy task. The double seam crease  74  is more appropriately used when the direction of corrugation of the flutes  55  of industrial reel wrap  50  extend cross-wise to the length of the industrial reel wrap  50 . In this instance, the corrugation of the flutes  55  works against the easy folding of the tabs  60  and the double seem crease  74  provides two flex points  76  at the seam enabling easier folding of the tabs  60 . 
     By using industrial, corrugated reel wrap  50  as described above, the time spent by an individual in preparing an industrial reel for shipment is reduced by greater than ⅓ when compared to traditional wood lagging. The time for removing industrial, corrugated reel wrap  50  is also significantly reduced over the removal time of wood lagging. Further, industrial, corrugated reel wrap  50  is of a greatly reduced weight, compared to wood, plywood, or Masonite® lagging, for reduced shipping costs. Further, the possibility of injury to the shipper or to the industrial reel contents is reduced by using fasteners of reduced length and preferred placement on end plate  16 . For example, staple prongs are of a significantly reduced length and width when compared to that of the shank of a nail which is used with wood lagging. Additionally, the shank of a nail used in fastening the present invention may be shorter than that used in wood lagging since the present invention is secured to exterior face  23  of end plate  16  rather than fully penetrating a piece of wood lagging and then being directed into the width of end plate  16  as is the case in wood lagging. 
     Further, by using industrial, corrugated reel wrap  50  as described above, only the circumference of an industrial reel  10  is wrapped, i.e., there is no direct contact with the contents of the industrial reel  10  when the contents assume a circumference that is less than the circumference of the end plates  16 . There is no possibility that the pattern of the industrial, corrugated reel wrap  50  is imprinted on the contents in this condition. When wrapping the circumference of the end plates  16  with industrial, corrugated reel wrap  50 , a substantially rigid material, the possibility that an object may break through wrap  50  to damage the contents of the industrial reel  10  is virtually eliminated unlike the alternative prior art method shown in FIG.  2 . Wrapping of the circumference with industrial, corrugated reel wrap  50  also provides a moisture barrier for the underlying contents of industrial reel  10 . 
     For shipping to customer locations wherein the industrial, corrugated reel wraps  50  will be applied to industrial reels  10 , the industrial reel wrap  50  is preferably provided with one or more scores  78 , FIG. 12 shows a preferred embodiment incorporating two, across the width of the industrial reel wrap  50 . The scores  78  preferably only penetrate one of the outside liners  52 ; the scores  78  do not continue down through the fluted center  54  or the second of the outside liners  52 . The scoring of the industrial reel wrap  50  enables the industrial reel wrap  50  to be folded, stacked atop each other, and atop a pallet for shipping. FIG. 13 shows a stack of tri-folded industrial reel wraps  50 , each of the reel wraps  50  has two scores  78  along its width. The cutting of only one of the outside liners  52  of the industrial reel wrap  50 , leaving the fluted center  54  and remaining outside liner  52  intact prevents the industrial reel wrap  50  from separating or splitting to ensure continuous and complete enclosure of the contents of the industrial reel  10 . 
     The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.