Patent Publication Number: US-2023138933-A1

Title: Cable reel

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present invention claims the benefit under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 63/275,100, which was filed on Nov. 3, 2021, in the names of Fred Dowd et al., the disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the storage of cables and, more particularly, to reels around which cables are wound for storage and ease of dispensing. 
     BACKGROUND OF THE INVENTION 
     A cable reel is a spool-like member around which an elongated product is tightly wound for compact storage and ease of dispensing. Most commonly, cable reels are designed to retain an item with a continuous filament-like construction, such as an elongated length of cable, wire, thread, fiber, or the like. 
     Cable reels are commonly adapted to receive a longitudinal crossbar, or spindle, which is in turn mounted onto a reel dispenser or rack. Pulling the free end of the product causes the cable reel to rotate about the spindle on which it is rotatably mounted. As such, a measured length of the product can be easily drawn from the reel and subsequently severed from the remainder of the supply to complete the dispensing process. 
     A traditional cable reel is constructed to include a tubular core, or drum, and a pair of disc-shaped flanges which are fixedly mounted on opposite ends of the drum. As such, an elongated cable is adapted to be wound onto the outer surface of the drum, with the pair of opposing flanges retaining the cable in place (i.e., preventing lateral displacement past either end of the core). 
     Although known in the art, traditional cable reels of the type as described above been found to suffer from a couple notable shortcomings. 
     As a first shortcoming, traditional cable reels of the type as described above are most commonly manufactured using wood, metal, or paper, which are all relatively expensive materials. Cable reels constructed of plastic are known in the art and are typically less expensive to manufacture. However, plastic cable reels have been found to be of limited strength and therefore are typically restricted to use in lightweight applications (e.g., cables of limited length and/or weight). 
     As a second shortcoming, a traditional cable reel of the type as described above is typically fixed in its construction with respect to certain material properties as well as overall dimensions. As a result, conventional cable reels are incapable of being modified in strength and/or size to accommodate significant variances between intended applications. 
     SUMMARY OF THE INVENTION 
     In view thereof, it is an object of the present invention to provide a novel cable reel on which can be wound a length of cable or other similar continuous filament-like item, such as wire, thread, fiber or the like. 
     It is another object of the present invention to provide a cable reel of the type as described above which has a limited number of parts, is constructed using inexpensive materials, and is easy to assemble. 
     It is yet another object of the present invention to provide a cable reel of the type as described above which is durable, sizable, and strong, thereby rendering it suitable for use with relatively long and/or heavyweight products. 
     It is still another object of the present invention to provide a cable reel of the type as described above which can be readily modified in strength and/or size to accommodate significant variances between intended applications. 
     Accordingly, as one feature of the present invention, there is provided a cable reel for retaining a length of product, the cable reel comprising (a) a tubular core comprising (i) a cylindrical barrel shaped to define an interior cavity, the barrel comprising an inner surface, an outer surface, a first end, and a second end, (ii) a first set of radial tabs formed on the first end of the barrel, each of the first set of radial tabs having an inner surface and an outer surface, and (iii) a second set of radial tabs formed on the second end of the barrel, each of the second set of radial tabs having an inner surface and an outer surface, (b) first and second inner flanges coaxially mounted on the barrel of the tubular core, the first inner flange disposed flush against the inner surface of the first set of radial tabs and the second inner flange disposed flush against the inner surface of the second set of radial tabs, and (c) first and second outer flanges, the first outer flange disposed flush against the outer surface of the first set of radial tabs and the second outer flange disposed flush against the outer surface of the second set of radial tabs, (d) wherein the first inner flange is fixedly secured to the first outer flange with the first set of radial tabs sandwiched therebetween and the second inner flange is fixedly secured to the second outer flange with the second set of radial tabs sandwiched therebetween. 
     Various other features and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawings which form a part thereof, and in which is shown by way of illustration, an embodiment for practicing the invention. The embodiment will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. The following detailed description is therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings, wherein like reference numerals represent like parts: 
         FIGS.  1 ( a ) and  1 ( b )  are assembled, front perspective and exploded, front perspective views, respectively, of a first embodiment of a cable reel constructed according to the teachings of the present invention; 
         FIGS.  2 ( a )- 2 ( d )  are rear perspective, left end, front, and bottom views, respectively, of the tubular core shown in  FIG.  1 ( b ) ; 
         FIG.  3    is a left end view of the disc-shaped, interior support flange shown in  FIG.  1 ( b ) ; 
         FIGS.  4 ( a ) and  4 ( b )  are front and left end views, respectively, of one of the inner flanges shown in  FIG.  1 ( b ) ; 
         FIGS.  5 ( a ) and  5 ( b )  are front and left end views, respectively, of one of the outer flanges shown in  FIG.  1 ( b ) ; 
         FIGS.  6 ( a ) and  6 ( b )  are assembled, front perspective and exploded, front perspective views, respectively, of a second embodiment of a cable reel constructed according to the teachings of the present invention; 
         FIGS.  7 ( a )- 7 ( d )  are rear perspective, top, left end, and front views, respectively, of the tubular core shown in  FIG.  6 ( b ) ; 
         FIGS.  8 ( a ) and  8 ( b )  are front plan and left end views, respectively, of a blank used to construct the tubular core shown in  FIG.  7 ( a ) ; 
         FIG.  9    is a left end view of the spacer flange shown in  FIG.  6 ( b ) ; and 
         FIGS.  10 ( a )-( c )  are a series of front perspective views of the cable reel shown in  FIG.  6 ( a )  at various stages of its assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Cable Reel  11   
     Referring now to  FIGS.  1 ( a ) and  1 ( b ) , there are shown assembled and exploded front perspective views, respectively, of a first embodiment of a cable reel constructed according to the teachings of the present invention, the cable reel being identified generally by reference numeral  11 . As will be explained in detail below, cable reel  11  is constructed of an inexpensive plastic material and is uniquely designed to allow for variability of its strength to accommodate different products. 
     In the description that follows, reel  11  is described as being designed for use in winding a length of cable, such as fiberoptic cable. However, it should be noted that reel  11  is not limited to use with cable. Rather, it is to be understood that reel  11  could be utilized to retain any continuous filament-like product, such as wire, thread, fiber, or the like, without departing from the spirit of the present invention. 
     As seen most clearly in  FIG.  1 ( b ) , cable reel  11  comprises (i) a tubular core, or drum,  13  with first and second sets of radial tabs  15  integrally formed at each of its ends, (ii) a disc-shaped, interior support flange  17  fixedly mounted within the interior of drum  13  to provide enhanced structural rigidity thereto, (iii) a pair of annularly-shaped inner flanges  19 - 1  and  19 - 2  coaxially mounted on core  13 , with one flange  19  disposed in direct abutment against the inner surface of a corresponding set of tabs  15 , and (iv) a pair of disc-shaped outer flanges  21 - 1  and  21 - 2 , with one outer flange  21  affixed to the outer surface of a corresponding inner flange  19  over its associated tabs  15  in order to secure the components together. It should be noted that the multi-flange construction utilized at each end of drum  13  allows for the material properties and thickness of the resultant flange to be modified, as needed, to meet any variances in strength required in the intended application, which is a principal object of the present invention. 
     Referring now to  FIGS.  2 ( a )-( d ) , tubular core  13  is constructed from a single sheet blank of corrugated plastic material. As can be appreciated, the use of an inexpensive plastic material to form most, if not all, of the various components of cable reel  11  serves to significantly reduce manufacturing costs, which is a principal object of the present invention. 
     As can be seen, the single sheet blank is rolled into a closed tube to create a central, cylindrical barrel  23  which is shaped to define an interior cavity  25 . Ends  27 - 1  and  27 - 2  of the single sheet blank are affixed together to secure the shape of barrel  23  and form a strengthening rib  29  which extends longitudinally within interior cavity  25  and assists in maintaining adequate structural rigidity to barrel  23 , as will be explained later. 
     First and second sets of radial tabs  15 - 1  and  15 - 2  are integrally formed onto open ends  23 - 1  and  23 - 2 , respectively, of barrel  23 . In the present embodiment, each set includes four, equidistantly arranged, arcuate-shaped tabs  15  that are integrally formed onto an end of barrel  23 . Each tab  15  includes a neck portion, or neck,  31  of reduced width which enables each tab  15  to be selectively bent from its initial orientation to an approximate right angle relative to barrel  23 , as shown herein. 
     It should be noted that core  13  is not limited to the particular number, shape, and arrangement of tabs  15  as shown herein. Rather, it is to be understood that the number, shape, and/or arrangement of tabs  15  on core  13  could be modified without departing from the spirit of the present invention. 
     As seen most clearly in  FIGS.  2 ( a ) and  2 ( c ) , a shortened slot  33  is formed in each side of barrel  23  at its approximate midpoint. As will be explained further below, slots  33  assist in retaining interior support flange  17  in place within interior cavity  25  of core  13 . 
     Referring now to  FIG.  3   , interior support flange  17  is shown in isolation. As can be seen, interior support flange, or support,  17  is constructed as a unitary, disc-shaped member  41 . Preferably, support  17  is made from an inexpensive and durable material, such as corrugated plastic. 
     A pair of arcuate protrusions  43  is formed on opposite sides of disc-shaped member  41 . Additionally, a radial slot  45  is formed in disc-shaped member  41  along its bottom edge. Lastly, a circular hole  47  is formed in disc-shaped member  41  at its approximate center point. 
     In use, support  17  is designed to be fixedly inserted into interior cavity of tubular core  13  and provide structural reinforcement thereto. Disposed as such, protrusions  43  extend partially through slots  33  in barrel  23  to help retain support  17  in place. Additionally, slot  45  in disc-shaped member  41  is dimensioned to fittingly receive longitudinal rib  29  of core  13  through a snap-in-place locking mechanism. 
     Preferably, the outer diameter of disc-shaped member  41  is approximately equal to the inner diameter of tubular core  13 . As a result, support  17  makes circumferential contact against the interior wall of barrel  23  and therefore provides the requisite structural integrity to core  13  to enable a cable (not shown) to be tightly wound thereon. The inclusion of hole  47  in support  17  enables a spindle (not shown) to be axially inserted through cable reel  11 . 
     Referring now to  FIGS.  4 ( a ) and  4 ( b ) , an inner flange  19  is shown in isolation. As can be seen, inner flange  19  is constructed as a unitary, annular member  51  which is shaped to define a circular center hole  53 , member  51  comprising a flattened outer surface  55  and a flattened inner surface  57 . Preferably, member  51  is made from an inexpensive and durable material, such as corrugated plastic. 
     In use, inner flange  19  is designed to be axially mounted over barrel  23  of tubular core  13 . As seen in  FIG.  1 ( b ) , inner flange  19  is preferably disposed along barrel  23  such that its outer surface  55  abuts directly against a corresponding set of tabs  15 . 
     As a feature of the present invention, aspects of inner flange  19  may be modified based on the strength requirements of the intended application. For instance, the density of the corrugated plastic material used to form inner flange  19  may be modified to enhance its strength. Additionally, as shown in  FIG.  4 ( a ) , the thickness T and/or the diameter D of inner flange  19  may be increased to improve the overall strength of the resultant cable reel without changing any other of its principal components. 
     Referring now to  FIGS.  5 ( a ) and  5 ( b ) , an outer flange  21  is shown in isolation. As can be seen, outer flange, or end cover,  21  is constructed as a unitary, disc-shaped member  61  which is shaped to define a circular center hole  63 , member  61  comprising a flattened outer surface  65  and a flattened inner surface  67 . Preferably, member  61  is made from an inexpensive and durable material, such as corrugated plastic. 
     In use, each end cover  21  is designed to coaxially align with its corresponding inner flange  19 , with inner surface  67  of end cover  21  directly facing outer surface  55  of its corresponding inner flange  19 . In turn, end cover  21  and inner flange  19  are secured together by any suitable means (e.g., using an adhesive, through welding, or the like), with the set of radial tabs  15  sandwiched therebetween. By fixedly securing together end cover  21 , inner flange  19 , and radial tabs  15 , a multi-piece flange is effectively created which is fixed in place on each end of barrel  23 . As previously referenced, the strength of the resultant multi-piece flange (and, in turn, the overall strength of cable reel  11 ) can be easily modified by changing characteristics of inner flange  19  (e.g., material density, thickness, and/or outer diameter). 
     Design Modifications and Alternate Embodiments 
     The invention described in detail above is intended to be merely exemplary and those skilled in the art shall be able to make numerous variations and modifications to it without departing from the spirit of the present invention. All such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims. 
     For example, referring now to  FIGS.  6 ( a ) and  6 ( b ) , there are shown assembled and exploded front perspective views, respectively, of a second embodiment of a cable reel constructed according to the teachings of the present invention, the cable reel being identified generally by reference numeral  111 . 
     Cable reel  111  is similar to cable reel  11  in that cable reel  111  comprises (i) a tubular core, or drum,  113  with first and second sets of radial tabs  115  integrally formed at each of its ends, (ii) a disc-shaped, interior support flange  117  fixedly mounted within the interior of drum  113  to provide enhanced structural rigidity thereto, (iii) a pair of annularly-shaped inner flanges  119 - 1  and  119 - 2  coaxially mounted on core  113 , with one flange  119  disposed in direct abutment against the inner surface of a corresponding set of tabs  115 , and (iv) a pair of disc-shaped outer flanges  121 - 1  and  121 - 2 , with one outer flange  121  affixed to the outer surface of a corresponding inner flange  119  over its associated tabs  115  in order to secure the components together. Also similar to cable reel  11 , cable reel  111  is preferably constructed of an inexpensive plastic material and is uniquely designed to allow for variability of its strength to accommodate different products. More specifically, the multi-flange construction utilized at each end of drum  113  allows for the material properties and thickness of the resultant flange to be modified, as needed, to meet any variances in strength required in the intended application. 
     Cable reel  111  differs primarily from cable reel  11  in (i) the construction of tubular core  113 , and (ii) the addition of a pair of spacer flanges, or spacers,  122 - 1  and  122 - 2  to minimize any gaps, or spacing, between inner flange  119  and its complementary outer flange  121 . 
     Referring now to  FIGS.  7 ( a )-( d )  and  FIGS.  8 ( a )-( b ) , tubular core  113  is similar to tubular core  13  in that tubular core  113  is constructed from a single sheet blank  123  of corrugated plastic material, as seen most clearly in  FIG.  8 ( a ) . As can be appreciated, the use of an inexpensive plastic material to form most, if not all, of the various components of cable reel  111  serves to significantly reduce manufacturing costs, which is a principal object of the present invention. 
     As seen most clearly in  FIGS.  7 ( a )-( d ) , single sheet blank  123  is rolled into a closed tube to create a central, cylindrical barrel  124  which is shaped to define an interior cavity  125 . Ends  127 - 1  and  127 - 2  of single sheet blank  123  are affixed together to secure the shape of barrel  124  and form a longitudinal strengthening rib  129  which assists in maintaining adequate structural rigidity to barrel  124 . 
     Core  113  is also similar to core  13  in that first and second sets of radial tabs  115 - 1  and  115 - 2  are integrally formed onto open ends  124 - 1  and  124 - 2 , respectively, of barrel  124 . However, although each set includes four, equidistantly arranged tabs  115 , the shape of each tab  115  differs from the shape of tab  15 . Notably, each tab  115  has a bulbous shape of limited surface area, for reasons to become apparent below. Tab  115  is integrally formed onto an end of barrel  124  through a neck portion, or neck,  131  of reduced width. Accordingly, each tab  115  is adapted to be selectively bent from its initial orientation to an approximate right angle relative to barrel  124 . 
     Finally, core  113  is similar to core  13  in that a shortened slot  133  is formed in each side of barrel  124  at its approximate midpoint. As can be appreciated, slots  133  assist in retaining interior support flange  117  in place within interior cavity  125  of core  113 . 
     Referring now to  FIG.  9   , a spacer  122  is shown in isolation. As can be seen, spacer  122  is constructed as a unitary, disc-shaped member  141 . Preferably, spacer  122  is made from an inexpensive and durable material, such as corrugated plastic. 
     A central hole  143  is formed in disc-shaped member  141  which enables spacer  122  to be coaxially mounted onto one end of barrel  124 . Hole  143  includes four bulbous cutouts  145  which are dimensioned to fittingly receive tabs  115  when cable reel  111  is in its assembled form. In this capacity, spacers  122  serve to minimize any gaps, or spacing, between inner flange  119  and its complementary outer flange  121 . Furthermore, because spacer  122  helps bond together inner flange  119  and outer flange  121 , the surface area of tabs  115  can be significantly reduced. 
     Referring now to  FIGS.  10 ( a )-( c ) , there is shown a series of front perspective views of cable reel  111  at various stages of its assembly. Although not shown herein, interior support flange  117  is preferably inserted into interior cavity  125  of barrel  124  and locked in place to provide structural rigidity to core  113 . Thereafter, first set of tabs  115 - 1  are temporarily articulated so as to extend in parallel to the longitudinal axis of barrel  124 . With tabs  115 - 1  configured as such, inner flange  119 - 1  is axially mounted onto barrel  124 . Then, tabs  115 - 1  are returned to an orthogonal orientation relative to barrel  124 . Lastly, inner flange  119 - 1  is then slid along barrel  124  so as to directly abut against first set of tabs  115 - 1 , as shown in  FIG.  10 ( a ) . 
     With inner flange  119 - 1  mounted as such, spacer  122 - 1  is mounted over core  113 , as shown in  FIG.  10 ( b ) . Because spacer  122 - 1  is designed to match the profile of tabs  115 - 1 , each tab  115  fittingly aligns within a corresponding cutout  145 . Preferably, the thickness of tabs  115  matches the thickness of spacer  122 , thereby together yielding a continuous, planar surface. 
     As seen in  FIG.  10 ( c ) , end cover  121 - 1  is disposed flush against spacer  122 - 1  and tabs  115 - 1  in coaxial alignment therewith. Thereafter, inner flange  119 - 1 , tabs  115 - 1 , spacer  122 - 1 , and end cover  121 - 1  are all secured together, such as through a welding process to yield a unitary, flange-like member on the end of core  113 . Although not shown herein, it is to be understood that inner flange  119 - 2 , spacer  122 - 2 , and end cover  121 - 2  are all mounted onto the opposite end of core  113  in a similar fashion. 
     As previously referenced, aspects of inner flanges  119  may be modified based on the strength requirements of the intended application. For instance, the density of the corrugated plastic material used to form each inner flange  119  may be modified to enhance its strength. Additionally, the thickness and/or diameter of inner flange  119  may be increased to improve the overall strength of the resultant cable reel without changing any other of its principal components.