Abstract:
Providing a spool end with a flange, a post, and a blade on the post which extends to the flange. The post is inserted into a core including penetrating the core with the blade. The spool end is rotated including imparting a rotating force upon the core using the blade. Preferably, at least three blades are used for stability and even transmission of rotational force.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    Reference is made to commonly assigned, co-pending U.S. patent application Ser. No. ______ by Richard S. Paoletti. (Docket 96724) filed of even date herewith entitled “Notchless Core”, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present application is directed to a method and apparatus for providing rotational force upon objects accessible via an opening having an inner diameter. 
       BACKGROUND OF THE INVENTION 
       [0003]    Rolled material supplied on full length spools or, optionally, on one or more spool ends typically require a core, a spool, or spool ends, formed for fitting on a complementary shaped rotating drive device such as providing a notch in the core for engaging a surface feature of the drive device, often referred to as a notch and key design. These are easy to use but can be expensive. Other methods include using a flange with both keys and straight ribs to transmit torque. These are difficult to use due to the force required to insert the flanges into the core. Roll fed printers that use cardboard cores for supplying wound media are an example. The cardboard core defines an inner diameter opening having a soft material core. Prior art approaches in this regard have relied on frictional engagement between a rotational drive means to transmit torque to the core/roll. This would require a certain amount of force to insert and remove the rolled media. Reduction of the insertion force has been achieved in other prior art by means of a spring loaded expansion of the roll after insertion. Other prior art methods involve blades fastened to a tube which is inserted into a media roll and engage the core at points near the middle of the length of the roll which also requires some manual effort to insert. 
       SUMMARY OF THE INVENTION 
       [0004]    Roll fed printers that use cardboard cores for supplying wound media are an example application of the means and methods of the present invention. The present invention does not rely on friction to transmit torque to the roll, thereby providing a more positive drive than frictional engagement, does not penetrate the core to any significant distance, and is simpler in construction. 
         [0005]    This can eliminate the need for a notched core for a roll of paper, for example. The notch feature can add significant expense to the core. The angle of the rib (blade) in the present invention allows for easy insertion and removal of the flanges into the core as opposed to other designs which require considerable force. By the use of angled ribs on the drive flange which penetrate into a soft core, such as cardboard, to transmit torque to the core. Media manufacturing cost is reduced due to elimination of core notching. 
         [0006]    A preferred embodiment of the present invention comprises a method comprising providing a spool end with a flange and a post. A blade on the post extends to the flange. The post is inserted into a core including penetrating the core with the blade, preferably in a radial direction. When inserted the core abuts the flange. The blade is disposed at an angle to the post such that the blade further penetrates the core as the post is further inserted into the core. The spool end is rotated including imparting a rotating force upon the core using the blade. Additional blades can be used on the post with each additional blade extending from the flange to the post. Preferably, at least three blades are used for stability and even transmission of rotational force. The blade or blades can optionally be disposed in a non-radial direction. 
         [0007]    Another preferred embodiment of the present invention comprises a method including inserting a post into a hollow core having rolled material wound thereon, and slicing into a portion of an interior diameter of the hollow core using a blade positioned on the post. Maintaining a position of the hollow core on the on the driving post keeps the blade in the hollow core. Rotating the post and the blade positioned on the post, including rotating the hollow core of rolled material, provides a rotational force by the blade against the hollow core of rolled material. The step of rotating can comprise controllably rotating the post for rotating the core and controllably stopping the rotation of the post for stopping rotation of the hollow core. A flange on the post limits an insertion distance of the post into the hollow core. The drive post is inserted into a first end of the hollow core and a support post can support a second end of the hollow core. 
         [0008]    Another preferred embodiment of the present invention comprises a method including forming a rib on a spool end, wherein the spool end is configured to be inserted into one end of a core of a spool and the rib is configured to cut and penetrate an inside diameter of one end of the core and remains penetrated so long as the spool remains on the spool end. The spool end is inserted into one end of the core and is rotated to rotate the spool typically to unwind the material off of the spool. The rib can be shaped to a height of about 0.20 inches and a length of about 0.25 inches extending in a radial direction from the spool end. Its height is less than a thickness of the core of the spool and its cutting edge forms an angle with respect to a length of the spool of about four to about five degrees. A second spool end (support spool) is configured to be inserted into a second end of the core of the spool and can be rotatable or stationary. 
         [0009]    These, and other, aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention and numerous specific details thereof, is given by way of illustration and not of limitation. For example, the summary descriptions above are not meant to describe individual separate embodiments whose elements are not interchangeable. In fact, many of the elements described as related to a particular embodiment can be used together with, and possibly interchanged with, elements of other described embodiments. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. The figures below are intended to be drawn neither to any precise scale with respect to relative size, angular relationship, or relative position, nor to any combinational relationship with respect to interchangeability, substitution, or representation of an actual implementation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIGS. 1A-B  illustrate a preferred embodiment of the present invention. 
           [0011]      FIG. 2  illustrates a media roll with a drive spool and support spool. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0012]      FIGS. 1A and 1B  illustrate a cross-section front view and a side view, respectively, of a preferred embodiment of the present invention wherein a spool end  110 , comprising a flange portion  101  attached to, or formed integrally with, substantially orthogonal post  103 , is provided with a blade, or rib,  102  that penetrates a hollow core  108  in order to transmit a rotational force (torque) to the core when the spool end is rotated by a motor (not shown) around rotational axis  109 . The blade as illustrated in  FIG. 1A  show a side profile of the blade which presents a triangular side surface of the blade which is in contact with the core  108  due to the blade penetrating the core. This surface area presses against the core when the flange/post assembly is rotated and so transmits rotational force to the core and any material wound thereon or attached thereto. The exposed, angled edge of the blade which contacts the core as the core is positioned on the post is referred to herein as the cutting edge.  FIGS. 1A-1B  illustrate one end of a hollow core  108  whose other end can be similarly constructed and also coupled to a post with or without a flange and with or without a blade as disclosed herein below with respect to  FIG. 2 . While the post and blade configuration disclosed herein is designed to co-rotate with the core and material wound thereon, the other end of the hollow core can be similarly constructed or it can be designed to slidably rotate around a stationary post. The blade is also affixed, attached, or formed integrally with, either, or both, the flange and the post. The blade first penetrates inner diameter  111  of the hollow core as the hollow core is positioned onto post  103  or as the post is inserted into the hollow core. Inner diameter  111  also represents the interior surface of hollow core  108  wherein the post is disposed. An opposite external surface is used for winding media or other material onto the hollow core. A greater height  105  of blade  102  results in a greater distance that the blade will penetrate the core. In the side view of  FIG. 1B , the flange  101  is not shown for purposes of clarity and the cross-section of the core  108  is shown to be circular, though this configuration is not a requirement. An outside diameter of post  103  is also circular to provide a good fit with, and is substantially equivalent to, the inside diameter  111  of hollow core  108  to provide stable and secure angular velocity thereto. Blade  102  penetrates core  108  when the post  103  is inserted into core  108  by sliding core  108  in direction  113  onto post  103 . The blade  102  can extend from the core radially, parallel to example radially extending lines  112 , or it can be disposed to extend from the core in a non-radial direction as shown by example blade  102   a.  The radial direction  112  aligns the blade along a line that intersects rotational axis  109 . Preferably, the blade extends from the post to the flange at an angle  104  facilitating easy positioning of the core onto the post to effect penetration of the blade into the core. This angle can be measured with reference to the rotational axis  109  or to the length of the core  108 . Typically wound around hollow core  108  is media (not shown) whose rolled depth around core  108  can extend up to, less than, or beyond the end of flange  101 , often referred to as a spool of media. The flange also serves as a terminus for the core, or spool, when the core is positioned on, or slid onto, the post and abuts the flange. Dotted line  108   a  indicates an optional thickness of core  108  which can extend beyond the height  105  of blade  102 . Dotted line  108   b  indicates that the thickness of core  108  can be less than the height  105  of blade  102 . If it is less than the height of blade  102  then the blade can also penetrate material rolled onto core  108 . It should be noted that a core is not required in order to implement the present invention, and that the post extension  103  and blade  102  can engage rolled material without a core. In such a case the blade  102  will penetrate the rolled material directly. In such a case the rolled material without a core can be directly represented as element  108 ,  108   a,  or  108   b,  in  FIGS. 1A and 1B . The length  106  and width  107  of the blade, or rib,  102  are described below. 
         [0013]      FIGS. 1A and 1B  are not intended to limit the configuration shown to a single spool end for driving core+rolled material or only rolled material. Another end of core  108  can also be fitted onto a similar bladed or non-bladed spool end  110 , as illustrated in  FIG. 2 , disposed to rotate coaxially with the spool end  110  or to remain stationary as core  108  rotates about it. In such a configuration, spool end  110  or both spool ends can be motor driven to rotate the core and rolled material around axis  109 . Similarly, multiple blades (not shown) similar to, or different from, blade  102  can be disposed around post, or extension,  103  to penetrate, engage, and provide rotational force to core  108  at multiple penetration points. In a preferred embodiment of the present invention, a minimum of three multiple blades are disposed at equidistant angular distances around the circumference of post  103  to insure stability and concentricity between the spool and core. The material wound around core  108  may be a continuous sheet of media, or it may comprise multiple individual sheets, or perforated sections, or other configurations of material, having a wide range of possible thicknesses. While the environment of the present invention was conceived and tested in the context of printer media, the invention is not limited thereto. The present invention comprises an apparatus and method of engaging a rotatable post to a hollow core for any application requiring such a configuration. While the material surrounding post  103  has been described as wound thereon, it need not be so configured. The material can be attached to post  103 , such as by adhesives, and the material itself may comprise an apparatus used for rollably applying liquids to surfaces and other objects, for example. Other uses of the presently described apparatus and method invention are considered part of the present invention. 
         [0014]      FIG. 2  illustrates the bladed drive spool  110 , described above, at one end of core  108  and a second bladed or non-bladed support spool  218 , shown as non-bladed, disposed at the other end of core  108 . The bladed drive spool  110  is shown with multiple blades  102 . Media  220  is shown wound around core  108  to a depth slightly less than the end of flange  101 . Drive gear or pulley  219  for rotating the flange/post assembly is also illustrated and is not explained further. 
         [0015]    Without limiting any dimensions in any manner whatsoever the elements shown in the Figures, the following are examples of the dimensions of preferred embodiments of the present invention as tested and designed by the inventors of the present invention, referring generally to  FIGS. 1A and 1B  and the description above. 
         [0016]    The Core ID was tested using a prototype of 3.009 inches with tolerance +/−0.008 inches. The mating post diameter was made at 2.995 inches with tolerance of +/−0.005 inches. Max core ID was determined to be 3.017 inches with materials available and Min flange OD was determined to be 2.990 inches with materials on hand. If the blade height is 0.020, the effective minimum flange OD is 3.030 to 3.040 inches, with resulting dimensions as follows:
       minimum blade engagement=(3.030−3.017)/2=0.013/2=0.0065″   maximum blade engagement=(3.04−3.001)/2=0.039/2=0.0195″       
 
         [0019]    The length and height of the blade can vary but should form an angle  104  of approximately 4 to 5 degrees with the axis of rotation  109  of the spool to minimize insertion force. Thus, in the above example of a blade height of 0.020″, the length of the rib  106  would be approximately 0.25″. 
         [0020]    The thickness of the rib  107  should be kept to a minimum to minimize insertion force but will depend on the rib material strength, hardness of the core it is being inserted into, and the torque transmitted per rib. A typical thickness would be 0.016″ to 0.020″ for use with a cardboard core. 
         [0021]    The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. 
       PARTS LIST 
       [0022]      101  Flange 
         [0023]      102  Blade 
         [0024]      102   a  Blade 
         [0025]      103  Extension 
         [0026]      104  Angle 
         [0027]      105  Height 
         [0028]      106  Length 
         [0029]      107  Width 
         [0030]      108  Core Thickness 
         [0031]      108   a  Core Thickness 
         [0032]      108   b  Core Thickness 
         [0033]      109  Axis 
         [0034]      110  Drive Spool 
         [0035]      111  Inner Diameter 
         [0036]      112  Radial Direction 
         [0037]      113  Direction 
         [0038]      218  Support Spool 
         [0039]      219  Motor or Pulley 
         [0040]      220  Media Roll