Patent Publication Number: US-7222818-B2

Title: Shipping spool

Description:
FIELD OF THE INVENTION 
   The invention relates to spools or reels upon which filaments including monofilaments such as wire, cable, or the like may be wound. 
   BACKGROUND OF THE INVENTION 
   It is known to provide spools or reels upon which filaments, including monofilaments such as wire, rope, or cable may be wound for subsequent shipment, storage, and use. Such reels typically include a central barrel connected to opposing end flanges. It is further known to provide a plurality of openings in the end flanges. For example, U.S. Pat. No. 3,942,741 (Hussar et al.) discloses a reel having flanges with a plurality of openings provided to reduce the amount of material used to fabricate the end flanges and to facilitate visual determination of the reel contents (the openings forming a plurality of view ports). 
   It is still further known to provide one or more dog holes adapted to receive a winding dog of a winding machine used to rotate the spool. For example, U.S. Pat. No. 6,715,710 (Russell et al.) discloses a cable reel having a such a dog hole. 
   A need exists for a reel which provides a novel arrangement of openings in the reel flange to provide visual access to the reel contents while also providing the flange with desirable structural stiffness characteristics. A further need exists for a reel having a novel dog hole design which receives a winding dog while maintaining a high level of structural rigidity. A reel combining these features would be particularly desirable. 
   SUMMARY OF THE INVENTION 
   In a first aspect, the invention is a spool comprising a barrel having a first end, a second end, a longitudinal centerline and an outer surface located at a first radius from the centerline. The spool further comprises first and second end flanges each having a hub portion and an annular rim portion. The annular rim portion has a radial span extending from an inner radius to an outer radius, the inner and outer radii each extending from a flange centerline. The inner radius is substantially equal to the first radius and each flange is fixedly coupled at the hub portion to the barrel at the first and second ends, respectively. A plurality of openings are each positioned at a different angular and radial location within the annular rim portion and have a size such that if the plurality of openings were rotated into angular alignment, the openings would extend over substantially the entire radial span of the annular rim portion. 
   Preferably, four openings are provided and are positioned at angular locations spaced approximately 90 degrees apart. Each of the first and second flanges may further have a first face and a second face. A circumferential rib may be fixed to the annular rim portion on the first face and extend around the annular rim portion proximate an outer circumference of the annular rim portion. A circumferential wall may be provided, connecting the hub portion to the annular rim portion. A first plurality of radial ribs may be fixed to the annular rim portion, the circumferential wall and the circumferential rib on the first face, extending between the circumferential wall and the circumferential rib. The hub portion may include a central arbor hole formed within an arbor sleeve and a second plurality of radial ribs located on the second face and fixed to the hub portion, arbor sleeve, and circumferential wall, extending between the arbor sleeve and the circumferential wall. Preferably, each flange is fabricated from a polymeric material and the hub portion and the annular rim portion each have a wall thickness in the range of 0.10 to 0.14 inches, the first plurality of radial ribs includes a total of twenty radial ribs, the second plurality of radial ribs includes a total of eight radial ribs, and each flange has an outer diameter of approximately 14 inches. 
   In a second aspect, the invention is a spool comprising a barrel having a first end and a second end. First and second end flanges are coupled to the barrel first and second ends, respectively. Each flange has a hub portion and a radially-extending, annular rim portion, a first face and a second face. A circumferential rib is fixed to the annular rim portion on the first face and extends around the annular rim portion proximate an outer circumference of the annular rim portion. A circumferential wall connects the hub portion to the annular rim portion. A plurality of radial ribs are fixed to the annular rim portion, the circumferential wall and the circumferential rib on the first face, extending between the circumferential wall and the circumferential rib. An opening is located within the annular rim portion and has a size extending substantially between the circumferential wall and the circumferential rib. A substantially transparent window is connected to the opening. 
   In a third aspect, the invention is a spool comprising a barrel having a first end and a second end. First and second end flanges are coupled to the barrel first and second ends, respectively, and each flange has a hub portion and a radially-extending, annular rim portion, as well as a first face and a second face. A circumferential rib is fixed to the annular rim portion on the first face and extends around the annular rim portion proximate an outer circumference of the annular rim portion. A circumferential wall connects the hub portion to the annular rim portion. A first plurality of radial ribs is fixed to the annular rim portion, the circumferential wall and the circumferential rib on the first face, extending between the circumferential wall and the circumferential rib. At least a sector of the annular rim portion is fabricated from a substantially transparent polymeric material. 
   In yet a fourth aspect, the invention is a spool for use with a winding machine having a winding dog to rotate the spool. The spool comprises a barrel having a first end and a second end. First and second end flanges are coupled to the barrel first and second ends, respectively. Each flange has a hub portion and a radially-extending, annular rim portion, as well as a first face and a second face. A circumferential rib is fixed to the annular rim portion on the first face and extends around the annular rim portion proximate an outer circumference of the annular rim portion. A circumferential wall connects the hub portion to the annular rim portion. A first plurality of radial ribs are fixed to the annular rim portion, the circumferential wall and the circumferential rib on the first face, extending between the circumferential wall and the circumferential rib. A generally semi-circularly shaped recess is located between two adjacent radial ribs, proximate the intersection of the ribs and the hub. The semi-circular recess has a center positioned in the range of 2.2 to 2.4 inches from the flange centerline and is adapted to receive the winding dog. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For the purpose of illustrating the invention, there is shown in the drawings a form of the invention which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown. In the drawings: 
       FIG. 1  is a perspective view of a shipping spool in accordance with a preferred embodiment of the present invention. 
       FIG. 2  is an elevational end view of the shipping spool of  FIG. 1 . 
       FIG. 3  is a plan view of an exterior face of a flange of the shipping spool of  FIGS. 1 and 2 . 
       FIG. 4  is a cross-sectional view of the flange of  FIG. 3 , taken along line  4 - 4  of  FIG. 3 . 
       FIG. 5  is a plan view of an interior face of the flange of  FIGS. 3 and 4 . 
   

   DETAILED DESCRIPTION OF THE DRAWINGS 
   Referring to the figures, wherein like numerals are used to indicate like elements throughout, there is shown in  FIGS. 1-5  a preferred embodiment of a shipping spool in accordance with the present invention, indicated generally by the reference numeral  10 . The spool  10  comprises a barrel  20  and two opposing end flanges  40  coupled to the barrel  20 . With particular reference to  FIGS. 1 and 2 , the barrel  20  has a first end  22 , a second end  24 , a longitudinal centerline  26  and an outer surface  28  located at a first radius  30  from the centerline  26 . The barrel  20  is preferably fabricated from conventional polymeric materials, such as acrylonitrile butadiene styrene or styrene, using conventional manufacturing techniques such as injection molding or extrusion. Preferably, the barrel is coupled to flanges  40  using conventional adhesive solvents or ultrasonic welding. 
   With particular reference now to  FIGS. 2-5 , the opposing end flanges  40  are identical. Each flange  40  has a hub portion  50  and an annular rim portion  70 . Preferably, the hub portion  50  is connected to the annular rim portion  70  by a circumferential wall  90 . The flanges  40  are preferably generally disk-shaped, having a central axis  42  which is generally coincident with the barrel longitudinal centerline  26  when the flanges  40  are assembled with the barrel  20 . Each flange  40  has a first face  44  and a second face  46 . When assembled with the barrel  20 , the first face  44  is oriented away from the barrel  20 , and thus may be characterized as an “exterior” face, while the second face  46  is oriented toward the barrel  20 , and thus may be characterized as an “interior” face. In one preferred embodiment, the flanges  40  each have an outer diameter of approximately 14 inches (355 mm). The flanges  40  may have a diameter larger or smaller than 14 inches. 
   A central arbor hole  52  is preferably provided in the hub portion  50 , formed by an arbor sleeve  56 . The arbor hole  52  has an arbor hole centerline  54 , which is generally coincident with the flange central axis  42 . The arbor hole  52  is adapted to receive an arbor or spindle (not illustrated), upon which the spool  10  may be supported for rotation about the arbor hole centerline  54 . A guide rib  58  preferably extends from the second face  46  in a divergent, radially expanding manner from the arbor sleeve  56  to form an opening larger than the arbor hole  54 . The guide rib  58  may be formed as a continuous ring member, or, as illustrated, may include a plurality of outwardly extending protrusions, each protrusion extending from a plurality of hub radial ribs  60 . When the spool  10  is fully assembled, a spindle (not illustrated) is first inserted from the side of the exterior face  44  through the arbor hole  54  in one of the flanges  40 . The spindle must then be inserted “blindly” from the side of the interior face  46 , through the arbor hole  54  in the second opposing flange  40 . The guide rib  58 , with its expanded opening, tends to help guide the spindle through the arbor hole  54  in the second opposing flange  40  during the blind insertion process. 
   Further preferably, the plurality of hub radial ribs  60  is provided, located on the second face  46  and fixed to the hub portion  50 , arbor sleeve  56 , and circumferential wall  90 , extending between the arbor sleeve  56  and the circumferential wall  90 . In the preferred embodiment illustrated, eight hub radial ribs  60  are provided. Alternatively, more or fewer hub radial ribs  60  could be provided. A plurality of hub angle brace ribs  62  may also be provided, located on the second face  46  and fixedly connected along a first edge  62   a  to the circumferential wall  90  and along a second edge  62   b  to the hub portion  50 . The hub portion  50  may include a plurality of drive holes  64 , sized, shaped, and positioned to receive drive members of winding machines. A collar  100  may be provided on the second face  46 , extending from the circumferential wall  90 , the collar  100  being sized and shaped to receive either of the barrel ends  22 ,  24 . 
   The annular rim portion  70  has a radial span extending from an inner radius  72  to an outer radius  74 , the inner and outer radii  72 ,  74  each extending from the flange centerline  42 . The inner radius  72  is substantially equal to the first radius  30 . Preferably, a circumferential rib  78  is fixed to the annular rim portion  70  on the first face  44  and extends around the annular rim portion  70  proximate the outer circumference of the annular rim portion. A plurality of annular rim radial ribs  80  may be fixed to the annular rim portion  70 , the circumferential wall  90  and the circumferential rib  78  on the first face  44 , the plurality of annular rim radial ribs  80  extending between the circumferential wall  90  and the circumferential rib  78 . In the embodiment illustrated, twenty annular rim radial ribs  80  are provided, but alternatively more or fewer ribs could be provided. A plurality of annular rim angle brace ribs  82  may be provided, located on the first face  44  and fixedly connected along a first edge  82   a  to the circumferential wall  90  and along a second edge  82   b  to the annular rim portion  70 . 
   Each flange  40  further comprises a plurality of openings  76 , which are each positioned at a different angular and radial location within the annular rim portion  70 , and which allow visual access to material wound on the spool  10 . The plurality of openings  76  are sized such that if the plurality of openings  76  were rotated into angular alignment, the openings  76  would extend over substantially the entire radial span of the annular rim portion. Stated differently, and with particular reference to  FIG. 5 , which illustrates a preferred embodiment having four openings  76 , positioned at angular locations spaced approximately 90 degrees apart, a first circle having a diameter D 1  intersects both a radially innermost opening  76   a  as well as a radially second-inner-most radially opening  76   b . Likewise, a second circle having a diameter D 2  intersects both the radially second-inner-most opening  76   b , as well as a radially second-outer-most opening  76   c . Still further, a third circle having a diameter D 3  intersects both the radially second-outer-most opening  76   c  as well as a radially outermost opening  76   d . Thus, if the openings  76   a - 76   d  were rotated into radial alignment, the openings would overlap, and form a single opening that would extend over substantially the entire radial span of the annular rim portion  70 . It will be understood that providing a plurality of relatively small openings  76  at various circumferential positions is desirable from a structural standpoint, allowing visual access to the spool contents over substantially the entire radial span of the annular rim portion  70 , while reducing the flexibility that would be introduced into the flange  40  if a single, larger opening were used in place of the multiple, smaller openings  76 . 
   Alternative approaches to providing visual access to materials wound on the spool  10  are possible. Rather than providing a plurality of openings  76 , a single opening (not illustrated), combined with a transparent window (not illustrated) connected to the opening, could also be used. The single opening (not illustrated) would be located within the annular rim portion and have a size extending substantially between the circumferential wall  90  and the circumferential rib  78 . A substantially transparent window (not illustrated) would be connected to the opening. The problem of increased structural flexibility resulting from the a single relatively large opening would be mitigated by providing the window. The transparent window and the remainder of the flange  40  could be joined during fabrication by conventional co-molding techniques. 
   As another alternative approach to providing visual access, at least a sector of the entire annular rim portion  70  could be fabricated from a substantially transparent polymeric material. Preferably, the entire annular rim portion  70 , or the entire flange  40 , could be fabricated from a transparent polymeric material such as a transparent form of acrylonitrile butadiene styrene. 
   The spool  10  is typically used in conjunction with a winding machine (not illustrated) having a winding dog (not illustrated). To facilitate operation of the spool  10  with the winding machine (not illustrated), the spool  10  may further comprise a generally semi-circularly shaped recess  110  formed in the circumferential wall  90  and located between two adjacent hub radial ribs  60 , proximate the intersection of the ribs  80  and the hub portion  50 . The semi-circular recess  110  has a center  112  positioned in the range of 2.2 to 2.4 inches from the flange centerline  42  and is sized and shaped to receive the winding dog (not illustrated). The semi-circular recess  110  provides a winding dog receptacle which maintains a continuous, unbroken circumferential wall  90 . Thus, the recess  110  imposes only a minimal effect on the structural stiffness characteristics of the flange  40 . Alternatively, if as an alternative design, a dog hole were to break the circumferential wall  90 , the flange stiffness characteristics would be substantially degraded. 
   Preferably, each flange  40  is fabricated from a polymeric material, such as acrylonitrile butadiene styrene (ABS), and the hub portion  50  and the annular rim portion  70  each preferably have a wall thickness in the range of 0.10 to 0.14 inches. The flanges  40  are preferably fabricated using conventional manufacturing techniques such as injection molding. 
   The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. 
   A shipping spool or reel is thus disclosed, providing a novel arrangement of openings in the spool flange to provide visual access to the spool contents while also providing the flange with desirable structural stiffness characteristics. Furthermore, the spool provides a novel dog hole design which receives a winding dog while maintaining a high level of structural rigidity. 
   Although the invention has been described and illustrated with respect to the exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. Accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.