Patent Publication Number: US-2002005029-A1

Title: Reel wrap

Description:
RELATED APPLICATION  
     [0001] The present application claims the benefit of U.S. Provisional Application No. 60/214,998 filed Jun. 29, 2000, which is incorporated herein in its entirety by reference. 
    
    
     
       FIELD OF THE INVENTION  
       [0002] The present invention relates to the protection of materials stored on a reel and, more particularly, to a corrugated wrap that is used to wrap the circumference of a reel thereby providing protection to the materials stored thereon.  
       BACKGROUND OF THE INVENTION  
       [0003] Traditionally, wooden spools or 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.  
       [0004] Referring to FIG. 1, the traditional, prior art manner of preparing a reel  10  for shipping through the use of wood lagging  12  is shown. 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 reel  10  to operate as a shipment, storage and dispensement container all in one. To prepare reel  10  for shipment, wood lags (lagging strips)  12  are placed one-by-one around the circumference of 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 reel  10 .  
       [0005] Each of the lagging strips  12  has been cut to the width of the 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 and varmints may attack the reel contents. The securing and subsequent removal of the lagging strips  12  from the reel  10  adds significant time, and resultant costs, to the 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 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 .  
       [0006] 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 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 reel through use of metal banding strips, leaving the end plates exposed.  
       [0007] 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 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 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 reel  10  is increased according to the pressure applied by metal banding strips  26  upon the contents.  
       [0008] The alternative described above with reference to FIG. 2 does significantly reduce the time needed to wrap and unwrap the reel, it does reduce the overall weight of the 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 reel  10 , there is the possibility that the pattern of the material  24  will be imprinted on the contents of the reel  10 . Further, because this alternative approach wraps the contents of the reel rather than the circumference of the end plates of the reel, there is a possibility that the exposed end plate  16  of a reel  10  will roll into the contents of another reel  10 , thereby damaging its contents.  
       [0009] 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  
       [0010] The needs described above are in large measure met by the corrugated reel wrap of the present invention. The reel wrap is designed to wrap a reel having a central spool that separates two end plates. The reel wrap generally comprises a substantially continuous central portion having two side portions operably coupled to a respective center portion side margin. Each of the side portions of the wheel wrap of the present invention include a number of tabs that are securable to the end plates of the reel. The width of the central portion is at least as wide as the reel, thereby allowing the central portion to span and enclose the area between the end plates of the reel.  
       [0011] The side portions are preferably unitary with the central portion allowing the complete reel wrap to be fabricated from a plastic or plasticized material, which preferably includes a corrugated layer that is laminated to a single face, or sandwiched between two faces. Since the reel is of a wood material, the tabs of the side portions of the reel wrap are preferably secured to the end plates of the reel with staples; however, other fasteners may be used. The tabs are configured to allow substantially gap-free contact between the central portion and the end plates when the tabs are secured to the end plates providing for the area intermediate the end plates of the reel to be substantially, completely enclosed.  
       [0012] The method for wrapping the reel wrap generally comprises the steps of placing or laying the wrap about the reel so that the central portion of the wrap covers the central spool, and securing the tabs to the exterior surface of the end plates of the reel with the previously described fasteners.  
       [0013] One object of the present invention is to utilize plastic or plasticized materials to better facilitate recyclability. In addition, the preferred materials provide flexibility in material colors, and even permit the use of translucent materials, simplifying visual inspections after the reel has been wrapped. This preferred material also provides increased protection and resistance from outside forces and elements.  
       [0014] Another object of the present invention is to provide a reel wrap weighing significantly less when compared to prior art lagging methods. This reduced wrap weight substantially reduces shipping costs.  
       [0015] Yet another object of the present invention is to minimize labor costs associated with reel preparation by significantly reducing the time taken to secure and remove the wrap. This object is achieved by implementing a generally unitary reel wrap and simpler fastening methods.  
       [0016] A further object of the present invention is to reduce the likelihood of injury to the person securing or removing the wrap from the reel. This injury reduction is achieved through the use of generally short fasteners which are directed to the exterior surface of the end plates rather than the edge of the end plates.  
       [0017] Yet a further object of the present invention is to provide a wrap that is easily modifiable so that it can be constructed in different shapes and sizes in accordance with specific needs generally associated with varying reel sizes.  
       [0018] The present invention is a reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, and a reel width extending from an outer margin of a first of the pair of end plates to an outer margin of a second of the pair of end plates. The reel wrap includes a wrap central portion, the central portion being substantially continuous and having a width between central portion edge margins at least coextensive with the width of the reel for spanning and enclosing an area between said pair of end plates. And the reel wrap includes first and second side portions for securing the central portion to the reel, the first and second side portions being securable to a respective side plate of the reel proximate a circumferential edge margin of the respective side plate of the reel. The present invention is further method of wrapping a reel. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0019]FIG. 1 is a prior art configuration of a reel, the contents of which have been protected through the use of wood lagging about the circumference of the reel;  
     [0020]FIG. 2 is a prior art configuration of a 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 reel;  
     [0021]FIG. 3 depicts a reel, the contents of which have been protected through the use of a corrugated reel wrap of the present invention;  
     [0022]FIG. 4 depicts a corrugated material that may be used in the corrugated reel wrap of the present invention;  
     [0023]FIG. 5 depicts an alternative corrugated material that may be used in the corrugated reel wrap of the present invention;  
     [0024]FIG. 6 depicts one pattern, having closely spaced tabs, for the corrugated reel wrap of the present invention;  
     [0025]FIG. 7 depicts an alternative pattern, having set-apart tabs, for the corrugated reel wrap of the present invention;  
     [0026]FIG. 8 depicts the corrugated reel wrap, with the pattern of FIG. 7, wrapped partially about a reel; and  
     [0027]FIG. 9 depicts the corrugated reel wrap of the present invention being applied to a reel through use of a pneumatic fastening tool. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0028] A 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 a reel. The corrugated reel wrap  50  provides for fast installation and removal, significantly reduces the amount of weight added to the reel compared to wood lagging, and reduces the possibility of injury to the shipper and/or contents of the reel.  
     [0029] Corrugated reel wrap  50  of the present invention is shown in FIGS.  3 - 5 . As FIG. 3 depicts, corrugated reel wrap  50  is designed to span the overall width of reel  10  and to be secured to the exterior of 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 reel  10  from damage. Referring to FIGS. 3 and 6, corrugated reel wrap  50  incorporates 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 , 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 . Corrugated reel wrap  50  may be of any desired length and width that is suitable to a specific application.  
     [0030] As FIG. 4 depicts, 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 a corrugated reel wrap  50  that preferably incorporates two outside liners  52  and a fluted center  54 , as shown in FIG. 4. Alternatively, 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 corrugated reel wrap  50 . Corrugated reel wrap  50  may be manufactured through lamination, extrusion, or other like processes.  
     [0031] Because 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 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 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 corrugated reel wrap  50  to be printed on easily and clearly, and to be tear, puncture, and impact-resistant for protection of the contents of reel  10 . The HDPE material also allows for 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, corrugated reel wrap  50  may be made with FDA approved resins.  
     [0032]FIGS. 7 and 8 depict corrugated reel wrap  50  incorporating an alternative 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 corrugated reel wrap 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  that is substantially equivalent in width to that of one of tabs  60 .  
     [0033]FIG. 9 depicts the application of corrugated reel wrap  50  to a reel  10 . As shown, 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 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 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 reel  10  until all tabs  60  are secured and the area intermediate end plates  16  of reel  10  is enclosed.  
     [0034] Completing the enclosure of the area intermediate end plates  16  may be achieved by overlapping the ends of corrugated reel wrap  50 . Using this manner of completing the enclosure allows for corrugated reel wrap  50  to be dispensed and cut to a desired length for application to reel  10 . Alternatively, corrugated reel wrap  50  may be manufactured to a specific length where the ends overlap to complete the enclosure. Within this alternative, if desired, the ends of 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.  
     [0035] By using corrugated reel wrap  50  as described above, the time spent by an individual in preparing a reel for shipment is reduced by greater than ⅓ when compared to traditional wood lagging. The time for removing corrugated reel wrap  50  is also significantly reduced over the removal time of wood lagging. Further, 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 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.  
     [0036] Further, by using corrugated reel wrap  50  as described above, only the circumference of a reel  10  is wrapped, i.e., there is no direct contact with the contents of the 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 corrugated reel wrap  50  is imprinted on the contents in this condition. When wrapping the circumference of the end plates  16  with corrugated reel wrap  50 , a substantially rigid material, the possibility that an object may break through wrap  50  to damage the contents of the reel  10  is virtually eliminated unlike the alternative prior art method shown in FIG. 2. Wrapping of the circumference with corrugated reel wrap  50  also provides a moisture barrier for the underlying contents of reel  10 .  
     [0037] 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.