Patent Publication Number: US-6991197-B2

Title: Webbed flange for a reel

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to reels for supporting wound flexible media, and in particular, to reels having a core and at least one flange that is attachable to the core. 
   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 a pressed paperboard material and 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 OF THE INVENTION 
   The present invention fulfills the above need, as well as others, by providing a reel including a flange that has features that inhibit bending and warping of the flange and that prevent damage to the core. More specifically, the flange includes support ridges on both its inner and outer sides for inhibiting bending, flexing, and warping of the flange. The flange also includes concentric walls that define a groove for receiving the end of the core. In addition to further inhibiting bending, flexing, and warping of the flange, the walls support the end of the core to thereby prevent damage thereto. 
   An exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes an elongated core defining a longitudinal core axis. The flange includes a first annular wall oriented substantially perpendicular to the axis and engaging the core. A second annular wall is oriented substantially perpendicular to the axis and is offset in an axial direction from the first annular wall. At least one connecting wall interconnects the second annular wall and the first annular wall. A first annular rim is attached to the first annular wall or the second annular wall and is oriented substantially parallel to the axis. 
   Another exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes an elongated core defining a longitudinal core axis. The flange includes a first annular wall having a center portion engaging the core. The first annular wall is oriented substantially perpendicular to the core axis when engaged to the core. A second annular wall is oriented substantially perpendicular to the core axis and is offset from the first annular wall in a first axial direction relative to the core axis. A plurality of circumferentially spaced substantially U-shaped support beams emanate radially from the center portion. Each of the support beams includes a pair of radially extending connecting walls oriented substantially parallel to the core axis and connected to the second annular wall. 
   Yet another exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes an elongated core defining a longitudinal core axis. The flange includes a first annular wall oriented substantially perpendicular to the axis. A plurality of first support ridges project from the first annular wall in a first axial direction substantially parallel to the axis. A second annular wall is oriented substantially perpendicular to the axis and is offset from the first annular wall in the first axial direction. The second annular wall is attached to the first annular wall. A plurality of second support ridges project from the second annular wall in a second axial direction substantially opposite to the first axial direction. The first support ridges and the second support ridges are all intersected by a common imaginary plane that is oriented substantially perpendicular to the axis. 
   A further exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes an elongated core defining a longitudinal core axis. The flange includes a first annular wall oriented substantially perpendicular to the axis and engaging the core. A plurality of first support ridges project from the first annular wall in a first axial direction substantially parallel to the axis. A second annular wall is oriented substantially perpendicular to the axis and is offset in the first axial direction from the first annular wall. The second wall is attached to the first annular wall. 
   A still further exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes an elongated core defining a longitudinal core axis. The flange includes a first annular wall oriented substantially perpendicular to the axis and engaging the core. A second annular wall is oriented substantially perpendicular to the axis and is offset in an axial direction from the first annular wall. The second annular wall is attached to and disposed radially outward of the first annular wall. A beam wall is oriented substantially coplanar with the first annular wall and is disposed radially outward of the first annular wall. At least one connecting wall interconnects the second annular wall and the beam wall. The beam wall and the at least one connecting wall define a support beam therebetween. 
   Another exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes a core. The flange includes an annulus having an inner side engaging the core. The inner side has a plurality of circumferentially-spaced indentations separated by a plurality of unindented portions interleaved between the indentations. The indentations are spaced around an entire circumference of the annulus such that each unindented portion spans less than 180° in a circumferential direction. 
   Yet another exemplary embodiment of the present invention includes a flange for use in a reel for supporting a wound flexible medium. The reel includes an elongated core defining a longitudinal core axis. The flange includes a substantially planar first web oriented substantially perpendicular to the axis. The first web includes a center portion engaging the core. A radially-oriented finger emanates from the center portion. A substantially planar second web is oriented substantially perpendicular to the axis and is offset in a first axial direction from the first web. The second web is attached to and disposed radially outward of the first web. At least one connecting wall interconnects the second web and the finger of the first web. The finger and the at least one connecting wall define a support beam therebetween. 
   An advantage of the present invention is that, because the flange includes support ridges on both of its sides, bending and warping of the flange is inhibited regardless of which of the two opposite axial directions a force is exerted on the flange. Yet another advantage is that the flange includes concentric walls defining a groove that supports and prevents damage to an end of the core that is received in the groove. 
   Still another advantage is that more structural strength of the flange can be achieved with less flange material than with prior flange designs. A more specific advantage is that he wall or web thickness of the flange material can be significantly reduced from prior flange designs. This reduction in thickness reduces material costs without sacrificing strength. A further advantage is that the inventive flange is easier to manufacture by standard injection molding processes, while minimizing hot spots or discontinuities in the molded material. 
   A further advantage of the present invention is that, by virtue of the support ridges and the concentric walls sharing a same position in the axial direction, the overall height of the flange is limited. These advantages, as well as particular benefits of the invention, 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 cutaway cross-sectional view of the reel along line  2 — 2  in  FIG. 1 ; 
       FIG. 3  shows a perspective view of one of the flanges of  FIG. 1 ; and 
       FIG. 4  shows an enlarged view of area A in  FIG. 2 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1  shows 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  each having a generally circular shape. It is noted that the core  12  typically, but not necessarily, has a substantially uniform shape along its length so the core assumes the configuration of a hollow cylinder. In the exemplary embodiment described herein, the core  12  can comprise a pressed paperboard 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. 
   The flange  14  comprises an annulus  18  having a plurality of circumferentially-spaced indentations  19  on a radially outer portion of an axially outer side  17  of the annulus  18 . The annulus  18  also has an inner annular rim  20  defining an inner edge  21  and an outer annular rim  22  defining an outer edge  23 , as shown in  FIG. 1 . The inner annular rim  20  extends axially inward, i.e., in a direction indicated by arrow  25 , from an axially outer first annular wall or planar web  24 , as shown in  FIG. 2 . The outer annular rim  22  extends axially outward, i.e., in a direction indicated by arrow  29 , from an axially inner second annular wall or planar web  26 . The axially outer first annular wall  24  and the axially inner second annular wall  26  are each oriented substantially perpendicular to the axis  13  and parallel to each other. The inner and outer rims  20 ,  22  are each oriented substantially parallel to the axis  13  and concentric with each other. In the exemplary embodiment described herein, the inner and outer rims  20 ,  22  are substantially circular. It will be noted however, that the exact shapes of the rims can be varied depending on the requirements of the application for the reel  10 . 
   As shown in  FIG. 2 , the outer annular wall  24  is displaced from the inner annular wall  26  in axial direction  29 . Emanating radially outwardly from the center portion  24   a  of the outer annular wall  24  are a plurality of fingers or support beam walls  39 . The beam walls  39  are generally coplanar with each other and with an annular, core-engaging center portion  24   a  of the outer annular wall  24 . The center portion  24   a  defines an axis that coincides with the core axis  13 . Some of the beam walls  39   a  are shorter than other beam walls  39   b . The inner annular wall  26  is connected to the walls  39  by radially extending connecting walls  27  and circumferentially extending end walls  43 . In the embodiment shown, the connecting walls  27  and end walls  43  are oriented parallel to the axis  13 . The support beam walls  39 , the connecting walls  27  and the end walls  43  form a plurality of beams or support beams  41  that are generally U-shaped in cross section. 
   As best seen in  FIGS. 3 and 4 , the flange  14  includes a circular groove  28  defined by the axially outer annular wall  24 , an axially extending annular inner hub wall  30  and an axially extending annular outer hub wall  32 . The inner hub wall  30  and outer hub wall  32  are concentric and provide the groove  28  with a shape that corresponds to the shape of the end  16   b  of the core  12 . Preferably, this shape is circular. The inner hub wall  30  extends axially inward from the outer annular wall  24 , as shown in  FIG. 4 . The outer hub wall  32  interconnects the outer annular wall  24  and the inner annular wall  26 , as seen in  FIG. 1 . Preferably, the outer hub wall  32  is integrated with the connecting walls  27  to provide flexural stiffness to the flange  14 . In a specific embodiment, the heights of both the inner hub wall  30  and the outer hub wall  32  are approximately between 0.25 inch and 1.0 inch. In the specific illustrated embodiment, both the inner hub wall  30  and the outer hub wall  32  have a height of approximately 0.625 inch. Each of the indentations  19  is defined by the outer rim  22 , two respective connecting walls  27 , and the outer hub wall  32 . 
   The groove  28  defined by the hub walls  30 ,  32  receives the end  16   b  of the core  12  therein such that the end  16   b  is surrounded by the wall  32  and the end  16   b  surrounds the wall  30 . More particularly, both the outer hub wall  24  and at least the proximal end of the inner hub wall  30  engage and support the end  16   b  of the core  12 . As can be seen in  FIG. 4 , the inner hub wall  30  angles or tapers radially inwardly toward the distal end of the wall  30  such that the distal end of the wall  30  may not engage the core  12 . This tapering of the groove  28  serves to guide the end  16   b  of the core  12  into the groove  28  and prevent damage to the end  16   b  as the end  16   b  enters the groove  28 . The base of the inner hub wall  30  can have a diameter greater than the inner diameter of the end  16   b  of the core  12  so that the wall  30  tends to angle the end  16   b  outward to help fix the end  16   b  in position. In a similar fashion, the flange  15  includes a groove  31  that receives and supports the end  16   a  of the core  12  therein. 
   The support of the inner hub wall  30  inhibits the end  16   b  from collapsing in a radially-inward direction. This support provided by the radially inner wall  30  may be particularly needed in the event of an external force being exerted upon the flange  14 . Without the support of the wall  30 , such an external force could cause the end  16   b  of the core  12  to collapse or buckle in the radially-inward direction. 
   The outer hub wall  32  does not normally engage the end  16   b  of the core  12 . Rather, there is a gap  33  between the outer hub wall  32  and the end  16   b  of the core  12 . However, if the core  12  were to buckle due to external forces, then the outer hub wall  32  may come into contact with and support the end  16   b  of the core  12 . The gap between the end  16   b  and the outer wall  32  can be generally on the order of one-sixteenth inch. Thus, the outer hub wall  32  can prevent further buckling and tearing of the core  12 . 
   In one aspect of the invention, the flange  14  can include a plurality of outer support ridges  34  extending in an axially outward direction from the inner annular wall  26 , as shown in  FIG. 1 . That is, the outer support ridges  34  project in axial direction  29  from the inner annular wall  26 . The support ridges  34  are preferably arranged in a web of radially-oriented ridges  36  and circumferentially-oriented ridges  38 . The radial ridges  36  bridge the radial space between outer hub wall  32  and rim  22 . The circumferential ridges  38  span the circumferential space between walls  27  of the support beams  39 . Radially innermost circumferential ridges  38   a  can intersect the radial ridges  36 . 
   Radially outermost ones  38   b  of the circumferential ridges are circumferentially aligned with the end walls  43  of the support beams  39 . As can be seen in  FIG. 1 , two of the ridges  38   b  interconnect the end walls  43  of one set of three adjacent support beams  39 , and the other two of the ridges  38   b  interconnect the end walls  43  of another set of three adjacent support beams  39 . The two sets of three support beams  39  are separated by shorter beams  39   a . Two opposing beams  39   b  are diametrically opposite each other and include discrete end walls  43   a  that do not engage any of the ridges  38   b.    
   In a further feature of the invention, an outer portion of an inner side  35  of the annulus  18 , i.e. the annulus side  35  that engages the core  12  and that is opposite the outer side  17 , has a plurality of circumferentially-spaced indentations  37  which are disposed so as to be complementary to the indentations  19  on the outer side  17  of the annulus  18 . Each of the indentations  37  is defined by the outer hub wall  32 , two respective connecting walls  27 , and a respective end wall  43 . Interleaved between and separating the indentations  37  are a plurality of unindented portions  45 . In other words, the unindented portions  45  of the web  26  are interleaved between the fingers  39 . The indentations  37  are spaced around an entire circumference of the annulus  18  such that each unindented portion  45  spans approximately between 10° and 60° in a circumferential direction indicated by double arrow  47 . Each unindented portion  45  is aligned in an axial direction with a respective indentation  19 . 
   The web  26  is in the form of an annular surface having discontinuities presented by the indentations  37 . Similarly, the web  24  is in the form of an annular surface having discontinuities presented by the indentations  19 . 
   The flange  14  can include a plurality of inner support ridges  40  extending in an axially inward direction  25  within the indentations  21  from the support beam walls  39 , as shown in  FIG. 3 . The support ridges  40  are arranged in a web of generally radially-oriented ridges  42  and circumferentially-oriented ridges  44 . The generally radially-oriented ridges  42  are disposed between the wall  32  and the end walls  43 . However, some of the radially-oriented ridges  42   a  essentially extend through wall  32  and are disposed inside the walls  30 ,  32 . These ridges  42   a  are connected to outer annular wall  24  to support the wall  24  and hub walls  30 ,  32  against diaphragm flexure. 
   The support beams  39 , support ridges  34 ,  40  and walls  30 ,  32  all increase structural strength of the flange  14  over prior flange designs. For instance, in response to external forces, the support beams  39 , support ridges  34 ,  40  and walls  30 ,  32  inhibit bending and warping of the flange  14 . The support beam construction of the present invention allows the flange  14  to have the same wall thicknesses as prior flange designs, but with greater structural strength. If desired, the flange walls of the present invention can alternatively be made thinner than prior flange designs while retaining the same strength as the flanges of the prior art. In one preferred embodiment, the flange walls have thicknesses approximately between 0.065 and 0.080 inch. 
   It may be ascertained from a comparison of  FIGS. 1 and 3  that sets of the outer support ridges  34  and sets of the inner support ridges  40  are disposed in a side-by-side, complementary fashion around the flange  14 . More specifically, sets of outer support ridges  34  and sets of inner support ridges  40  can be alternatingly disposed around the flange  14  in a circumferential direction. In a preferred embodiment, no set of outer support ridges  34  shares the same angular position with any set of inner support ridges  40 . For example, a set  46  ( FIG. 1 ) of outer support ridges  34  is disposed between sets  48  and  50  ( FIG. 3 ) of inner support ridges  40 . 
   All outer support ridges  34  and inner support ridges  40  share a same position in the axial direction. Further, the outer and inner support ridges  34 ,  40  also share a same axial position with the radially inner and outer walls  30 ,  32 . That is, the outer and inner support ridges  34 ,  40  and the groove  28  are disposed at a same position along the axis  13  of the core  12 . An imaginary radially-oriented plane  82  oriented perpendicular to the axis  13  can simultaneously intersect each of the outer and inner support ridges  34 ,  40  and the radially inner and outer walls  30 ,  32 . Thus, a height  52  ( FIG. 2 ) of the flange  14 , and the space occupied thereby, are advantageously minimized. 
   The flange  14  includes two diametrically opposed feed slots  54   a ,  54   b  ( FIGS. 1 ,  3 ), each of which creates a respective discontinuity in both the radially inner wall  30  and the radially outer wall  32 . An end of a wire, cable, or other medium that is wound on the reel  10  can be threaded through one of the slots  54   a ,  54   b  and secured to the flange  14  without having to cross the outer annular rim  22 . 
   The axially inner annular wall  26  includes four ramps  56   a ,  58   a  and  56   b ,  58   b . The ramps provide the wound medium with a gradual transition from the plane of the axially inner annular wall  26  to the slots  54   a ,  54   b . Thus, there is no need to bend the wound medium at a ninety degree angle in order that the medium can pass through a slot. A 90 degree angle may be difficult to achieve if the wound medium is relatively thick. The gradual transition provided by the ramps also avoids the wound medium engaging a sharp corner of the flange  14  as the wound medium passes into the slot. Such a sharp corner could damage the wound medium. 
   Each of the ramps  56   a ,  58   a  and  56   b ,  58   b  can extend into a respective set of inner support ridges  40 . That is, each of the ramps is partially formed by the distal edges of a respective set of inner support ridges  40 . More particularly, the ramp  56   a  extends into a ridge set  60 ; the ramp  58   a  extends into a ridge set  62 ; the ramp  56   b  extends into the ridge set  50 ; and the ramp  58   b  extends into a ridge set  64 . The heights of the ridges  40  change gradually along the ramps in order to provide a smooth transition. 
   Another advantageous feature of the present invention is that a number of the circumferentially-oriented ridges  44  can be aligned with the ramps. For example, it can be seen in  FIG. 3  that two of the circumferentially-oriented ridges  44  of the ridge set  50  are disposed in the small area of the set  50  that is aligned with the ramp  56   b . It can also be seen that only one of the ridges  44  is disposed in the much larger area of the set  50  that is not aligned with the ramp  56   b . The circumferentially-oriented ridges  44  that are aligned with the ramps provide additional support for the wound medium that engages the ramps. The support provided by the circumferentially-oriented ridges  44  within the ramps prevents the radially-oriented ridges  42  within the ramps from cutting into the wound medium and possibly damaging the wound medium. 
   It is noted that while only the first flange  14  is discussed above in detail, the second flange  15  preferably has the same structure. 
   During assembly, the core  12  may be further secured to the flanges  14 ,  15  by use of staples. More particularly, staples  66  ( FIG. 1 ) may be driven through the radially outer wall  32  and into the core  12 . Although only two staples  66  are shown in  FIG. 1 , additional staples  66  can be inserted at various locations along the periphery of the radially outer wall  32 . Similarly, staples can be driven into the radially outer wall of the flange  15  in order to secure the core  12  to the flange  15 . 
   As an alternative to staples, 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  68  of the flange  14  and into the aligned bolt holes  70  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 . Alternatively, or in addition, the bolts can be inserted through the countersunk bolt holes  72  of the flange  15  and into the aligned bolt holes  74  in the flange  14 . 
   During use, a user may grab the flange  14  around its outer annular rim  22  and manually lift the reel  10  off of the floor in the upward direction indicated by arrow  76  in  FIG. 1 . While the reel  10  is held by the flange  14  and suspended off of the floor, the weight of the reel  10  imparts a bending force on the flange  14 , tending to bend the outer portion of the flange  14  that is gripped by the user. The gripped outer portion of the flange  14  can be bent by the reel weight in either of two directions, i.e, in either the outward direction  78  or the inward direction  80  ( FIG. 2 ), depending upon the orientation in which the reel  10  is held. 
   The flange  14  can also be bent in either of two directions if the user grips the flange  14  with both hands at two diametrically opposite points. For instance, if the two-handedly gripped flange is oriented substantially horizontal and disposed above the ungripped flange, i.e., with the weight of the reel pulling down on the gripped flange, then the edges of the gripped flange will tend to bend in the outward direction. If the two-handedly gripped flange is oriented substantially horizontal and disposed below the ungripped flange, i.e., with the weight of the reel pushing down on the gripped flange, then the edges of the gripped flange will tend to bend in the inward direction. 
   Bending of the flange  14  in the outward direction  78  tends to compress the outer support ridges  34  and stretch out the inner support ridges  40 . It has been found that ridges are generally more resistant to being stretched than they are to being compressed. That is, ridges tend to buckle while being compressed, but hold up relatively well while being stretched. Thus, when an outward force in direction  78  is exerted upon the flange  14 , it is primarily the stretched inner support ridges  40  rather than the compressed outer support ridges  34  that inhibit bending and warping of the flange  14 . 
   If the flange  14  is bent in the inward direction  80 , then it is the inner support ridges  40  that are compressed and the outer support ridges  34  that are stretched. Thus, in this case, it is primarily the stretched outer support ridges  34  rather than the compressed inner support ridges  40  that inhibit bending and warping of the flange  14 . 
   As is evident from the above description, in order to inhibit bending and warping, it is advantageous for ridges to be on both sides (i.e., the inner side and the outer side) of a flange so that some ridges are stretched rather than compressed regardless of which direction the flange is bent. Thus, some ridges are always positioned to be stretched, and can thereby best inhibit bending and warping of the flange. The flange of the present invention provides such an arrangement by including both sets of outer support ridges  34  and sets of inner support ridges  40  alternatingly disposed around the flange  14 . Further, by the sets of outer support ridges  34  and sets of inner support ridges  40  being widely dispersed around the flange  14 , it is ensured that a stretched ridge is in close enough proximity to inhibit bending and warping of the flange  14  regardless of where along its periphery the flange  14  is gripped and regardless of in which direction the bending force is exerted. 
   It will be appreciated that the above described embodiments are merely exemplary, and 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 outer support ridges  34 , the spacings 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 spacings 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.