Patent Description:
Filament products can be supplied to end users on storage spools. The filament product can include new filaments and/or existing filaments that are going to be left on a reel for any length of time. The storage spool can protect the filament product during shipping, handling, and general use.

With conventional storage spools, there are two commonly used methods for supplying the filament product. The filament is either directly wound onto the spool, or the filament is wound into a loose coil and placed onto the spool. Typically, fly fishing lines are packaged based on the latter method. The spool includes an arbor for supporting the filament and two flanges for retaining the filament on the arbor. To allow the loose coil to be placed onto the arbor, the spool can be separated into at least two parts, and the flanges can be separated from one another to allow the coil to be placed on the arbor. Enough clearance must be provided between the internal diameter of the coil and the outside diameter of the arbor of the spool to allow the coil to be loaded onto the arbor. However, multiple part spools have drawbacks. For example, there is a potential to pinch the filament between mating surfaces of the spool parts, which can ruin the filament product. Further, the multiple parts can inadvertently separate while in use at high speeds causing tangling, bending, or other damage to the filament. Also, many conventional storage spools are made of plastic, and are discarded after the filament has been dispensed.

<CIT> describes a one-piece reel arrangement formed of a substantially quadrangle planar sheet. <CIT> describes spools for carrying rolls of narrow fabrics and methods of mounting rolls of material on packing spools.

The foregoing needs are met, to a great extent, by the spool assembly of this disclosure. There is a global push to reduce single use plastic products. The spool assembly disclosed herein comprises a single piece paperboard spool that is eco-friendly and solves the short comings of the multiple piece spool designs.

The present invention provides a spool for supporting a roll of material according to claim <NUM>. The spool comprises an arbor, a first flange, and a second flange. The arbor extends about an arbor axis and includes a plurality of arbor panels connected to each other and spaced about the arbor axis. The first and second arbor panels of the plurality of arbor panels each include a first arbor edge, and a third arbor panel of the plurality of arbor panels includes a second arbor edge. The first arbor edges of the first and second arbor panels are spaced from the second arbor edge of the third panel in an arbor direction, which is substantially parallel to the arbor axis.

The first flange includes a first plurality of flange panels. A first flange panel of the first plurality of flange panels is rotatably connected to the first arbor edge of the first arbor panel, and a second flange panel of the first plurality of flange panels is rotatably connected to the first arbor edge of the second arbor panel. The second flange is connected to the second arbor edge of the third arbor panel.

The first flange is configured to transition between a retention configuration and an open configuration. In the retention configuration, the first and second flange panels of the first plurality of flange panels extend from the respective first arbor edges to a retention height. In the open configuration, the first and second flange panels of the first plurality of flange panels extend from the respective first arbor edges to an open height. The retention height and the open height extend in a flange direction from the arbor axis. The flange direction is substantially perpendicular to the arbor axis. The retention height is greater than the open height such that in the retention configuration, the roll of material is substantially prevented from removal from the arbor along the arbor axis by the first and second flanges, and in the open configuration, the roll of material is removable from the arbor in the arbor direction.

The present invention further provides a method of assembling a paperboard spool from a one-piece paperboard blank according to claim <NUM>. The method comprises: connecting a first arbor panel of a plurality of arbor panels to a second arbor panel of the plurality of arbor panels, wherein the first and second arbor panels form at least a portion of an arbor that extends about an arbor axis; forming a first flange panel crease line between the first arbor panel and a first flange panel of a first plurality of flange panels such that the first flange panel is rotatable relative to the first arbor panel; and forming a second flange panel crease line between the second arbor panel and a second flange panel of the first plurality of flange panels such that the second flange panel is rotatable relative to the second arbor panel.

The first plurality of flange panels compose a first flange that is configured to transition between a retention configuration and an open configuration. In the retention configuration, the first and second flange panels of the first plurality of flange panels extend from the respective first and second arbor edges to a retention height. In the open configuration, the first and second flange panels of the first plurality of flange panels extend from the respective first and second arbor edges to an open height. The retention height is greater than the open height.

An aspect of the disclosure provides a spool that holds an item that can be coiled. The spool includes a barrel and spaced flanges. The item to be carried by the spool is disposed on the barrel between the flanges. One of the flanges is collapsible to allow an item that is already coiled to be loaded onto the barrel. In the collapsed condition, the collapsible flange is substantially the same size in cross section as the barrel. In one configuration, the collapsible spool is tapered down in cross section away from the barrel to facilitate loading of the coiled item on the spool.

Another aspect of the disclosure provides a spool that is made from a foldable material such as a paperboard or a polymer board. The spool is provided in the form of a flat blank with fold lines scored, cut, or embossed. The spool is erected and adhesive and interlocking elements are provided to maintain the erected condition. In one configuration, the spool can be partially erected into an intermediate condition where it is flat for convenient storage and shipping. In this configuration, the final erection step does not require additional adhesive to complete the erection of the spool.

Another aspect of the disclosure provides a method for loading a coiled item on a spool which includes the steps of collapsing a flange of the spool to a cross section no larger than the cross section of the barrel, sliding the coiled item over the collapsed flange and onto the barrel, and then unfolding the collapsed flange to its expanded condition where it retains the coiled item on the barrel.

Another aspect of the disclosure provides a method for forming a spool wherein a blank is provided and erected to a generally flat intermediate condition with portions secured by adhesive. Later, after the adhesive is cured, the spool is erected into its erected condition using only interlocking connections that do not require adhesive.

Another aspect of the disclosure provides a paperboard spool for fly fishing line wherein the spool can be erected from a flat blank. The spool includes a barrel formed from four walls. Two flanges project outwardly from the outer perimeter of the barrel. The spool provides a collapsible flange that collapses to a loading condition wherein the collapsed flange is in the form of a pyramidal frustum formed by folding corner webs inwardly. The spool has an intermediate condition during its erection wherein all of the adhesive connections are made and wherein the spool can be placed in a substantially flat condition with the barrel walls being parallel and folded down to be substantially parallel with the flanges.

The foregoing summary, as well as the following detailed description of illustrative embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the present application, there are shown in the drawings illustrative embodiments of the invention. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:.

<FIG> illustrate a spool <NUM>, according to an aspect of this disclosure. The spool <NUM> includes an arbor <NUM>, a first flange <NUM>, and a second flange <NUM>. The arbor <NUM> is configured to support a roll or coil of material <NUM> thereon. The spool <NUM> can comprise a paperboard material, which can be folded and bent to form fold lines and/or crease lines spool <NUM>. In an aspect, the spool <NUM> comprises a single piece of paperboard material. The single piece spool <NUM> is configured such that one or both of the first and second flanges <NUM> and <NUM> can transition between a retention configuration and an open configuration, as further described below. In the retention configuration, the roll of material <NUM> is retained on the arbor <NUM> (see <FIG>). In an open configuration, the roll of material <NUM> is removable from the arbor <NUM> (see <FIG>).

The arbor <NUM> extends about an arbor axis <NUM>. In an aspect, the arbor axis <NUM> extends through a radial center of the arbor <NUM>. The arbor <NUM> includes a plurality of arbor panels <NUM>. Each of the arbor panels <NUM> is connected to each of the other arbor panels <NUM> in series. For example, a first arbor panel 110a is connected to a second arbor panel 110b. In an aspect, the plurality of arbor panels <NUM> comprises four panels (as illustrated), such that the arbor <NUM> forms a substantially rectangular cross-sectional shape when viewed along the arbor axis A. It will be appreciated that the arbor <NUM> can comprise a different number of panels. For example, the arbor <NUM> can comprise three panels or five or more panels.

Each of the arbor panels <NUM> includes a first arbor edge <NUM> and a second arbor edge <NUM>. Each of the first arbor edges <NUM> is spaced from the respective second arbor edge <NUM> in an arbor direction A. The arbor direction A is substantially parallel to the arbor axis <NUM>. Each of the arbor panels <NUM> further includes a third arbor edge <NUM> and a fourth arbor edge <NUM>. The third arbor edge <NUM> of an arbor panel <NUM> is connected to a corresponding fourth arbor edge <NUM> of an adjacent arbor panel <NUM>. For example, the third arbor edge <NUM> of the first arbor panel 110a is connected to the fourth arbor edge <NUM> of the second arbor panel 110b. Similarly, the third arbor edge <NUM> of the second arbor panel 110b is connected to a fourth arbor edge <NUM> of a third arbor panel 110c (see <FIG>).

In an aspect, the third and fourth arbor edges <NUM> and <NUM> of each arbor panel <NUM> extend in a direction substantially parallel to the arbor axis <NUM>. The first, second, third, and fourth arbor edges <NUM>, <NUM>, <NUM>, and <NUM> can define a substantially rectangular arbor panel <NUM>. In an alternative aspect, the third and fourth arbor edges <NUM> and <NUM> are angularly offset from one another (e.g. not substantially parallel to one another), such that each arbor panel <NUM> includes a trapezoid shape, rhombus shape, combinations thereof, or other quadrilateral shape. In another alternative, each arbor panel <NUM> can include fewer or more than four arbor edges and can define a triangular shape, hexagon shape, combinations thereof, or other shape. In an aspect, each arbor panel <NUM> is substantially planar such that each arbor edge (e.g. edges <NUM>, <NUM>, <NUM>, and <NUM>) extends along a substantially similar plane.

The connection between the respective third and fourth arbor edges <NUM> and <NUM> of adjacent arbor panels <NUM> can include a crease line. The crease line can include a fold or bend in the spool <NUM> material. The crease line can allow each arbol panel <NUM> to rotate relative to an adjacent arbor panel <NUM> about the crease line. It will be appreciated that the connection between respective third and fourth arbor edges <NUM> and <NUM> can comprise other types of rotatable connections that allow the arbor panels <NUM> to rotate relative to adjacent arbor panels <NUM>.

The first arbor edge <NUM> of each arbor panel <NUM> is rotatably connected to the first flange <NUM>. The rotatable connection between each first arbor edge <NUM> and the first flange <NUM> can include a crease line. The crease line can include a fold or bend in the spool <NUM> material. In an aspect, the first arbor edge <NUM> of every arbor panel <NUM> is rotatably connected to the first flange <NUM>. Alternatively, fewer than all the first arbor edges <NUM> of each arbor panel <NUM> are connected to the first flange <NUM>. For example, an arbor <NUM> that includes four arbor panels <NUM> can have two first arbor edges <NUM> of two of the arbor panels <NUM> connected to the first flange <NUM>, while two first arbor edges <NUM> of two of the other arbor panels <NUM> are not connected to the first flange <NUM>.

The second arbor edge <NUM> of each arbor panel <NUM> is rotatably connected to the second flange <NUM>. The rotatable connection between each second arbor edge <NUM> and the second flange <NUM> can include a crease line. The crease line can include a fold or bend in the spool <NUM> material. In an aspect, the second arbor edge <NUM> of every arbor panel <NUM> is rotatably connected to the second flange <NUM>. Alternatively, fewer than all the second arbor edges <NUM> of each arbor panel <NUM> are connected to the second flange <NUM>. For example, an arbor <NUM> that includes four arbor panels <NUM> can have two second arbor edges <NUM> of two of the arbor panels <NUM> connected to the second flange <NUM>, while two second arbor edges <NUM> of two of the other arbor panels <NUM> are not connected to the second flange <NUM>.

The connection between the first arbor edges <NUM> of each arbor panel <NUM> with the first flange <NUM> and the connection between the second arbor edges <NUM> of each arbor panel <NUM> with the second flange <NUM> can be substantially symmetric when viewed in a direction substantially perpendicular to the arbor axis <NUM>. For example, each first arbor edge <NUM> and each second arbor edge <NUM> can be connected to the respective first flange and second flange <NUM> and <NUM> in a substantially similar manner. In an alternative aspect, each arbor panel <NUM> that has a first arbor edge <NUM> connected to the first flange <NUM> has a second arbor edge <NUM> that is not connected to the second flange <NUM>. And each arbor panel <NUM> that has a second arbor edge <NUM> connected to the second flange <NUM> has a first arbor edge <NUM> that is not connected to the first flange <NUM>. In this aspect, the first and second flanges <NUM> and <NUM> are circumferentially offset from each other when viewed along the arbor axis <NUM>. It will be appreciated that other alternative connections between the arbor panels <NUM> and the first and second flanges <NUM> and <NUM> can be considered that are consistent with the aspects described herein.

The first flange <NUM> includes a first plurality of flange panels <NUM>. The first plurality of flange panels <NUM> comprises a first inner plurality of flange panels <NUM> and a first outer plurality of flange panels <NUM>. The first inner plurality of flange panels <NUM> extend from the arbor <NUM> to the first outer plurality of flange panels <NUM>. The first outer plurality of flange panels <NUM> extend to an end <NUM> of the first flange <NUM>.

Each of the first arbor edges <NUM> of the arbor panels <NUM> is rotatably connected to a respective one of the first inner plurality of flange panels <NUM>. For example, the first arbor panel 110a is rotatably connected to a first inner flange panel 118a. Similarly, the second arbor panel 110b is rotatably connected to a second inner flange panel 118b. Each of the first outer plurality of flange panels <NUM> is rotatably connected to an edge of a respective one of the first inner plurality of flange panels <NUM>. The rotatable connection between each of the panels <NUM>, <NUM>, and <NUM> can include a crease line formed in the material composing the spool <NUM>.

The rotatable connection between each first arbor edge <NUM> of the arbor panels <NUM> and the respective one of the first inner plurality of flange panels <NUM> can extend in a direction that is substantially perpendicular to the arbor axis <NUM>. Each of the first inner plurality of flange panels <NUM> can rotate between at least <NUM> degrees and <NUM> degrees relative to the respective arbor panel <NUM> to which the inner flange panel <NUM> is connected. For example, when one of the first inner plurality of flange panels <NUM> is rotated approximately <NUM> degrees relative to the respective arbor panel <NUM> to which it is connected, the inner flange panel <NUM> extends in a direction away from (e.g. radially outward) the arbor axis <NUM> such that the flange panel <NUM> is substantially perpendicular to the arbor axis <NUM>. When one of the first inner plurality of flange panels <NUM> is rotated approximately <NUM> degrees relative to the respective arbor panel <NUM> to which it is connected, the inner flange panel <NUM> extends in a direction substantially parallel to the arbor axis <NUM>. In this orientation (e.g. <NUM> degree rotation), the inner flange panel <NUM> can be substantially planar with (e.g. align along the same plane) the respective arbor panel <NUM> to which it is connected. It will be appreciated that each of the first inner plurality of flange panels <NUM> can rotate to an angle relative to the respective arbor panel <NUM> to which it is connected that is greater than <NUM> degrees and less than <NUM> degrees to facilitate receiving and retaining the roll of material <NUM> onto the arbor <NUM>, as further described below.

With reference to <FIG> and <FIG>, each of the first outer plurality of flange panels <NUM> is connected to a respective edge <NUM> of one of the first inner plurality of flange panels <NUM>. Each of the first outer plurality of flange panels <NUM> is rotatable relative to the respective one of the first inner plurality of flange panels <NUM> about the edge <NUM>. In an aspect, the edge <NUM> can be substantially perpendicular to the arbor axis <NUM>. For example, when a first inner flange panel 118a of the first inner plurality of flange panels <NUM> is positioned at <NUM> degrees relative to the respective arbor panel 110a, an edge 122a extends substantially perpendicular to the arbor axis <NUM>. It will be appreciated that the edge <NUM> can extend at other angles other than substantially perpendicular to the arbor axis <NUM> when the first inner flange panel is greater than <NUM> degrees. For example, when the first inner flange panel 118a is positioned at approximately <NUM> degrees relative to the respective arbor panel <NUM>, the edge 122a can extend at an angle other than substantially perpendicular to the arbor axis <NUM>.

The first plurality of flange panels <NUM> further includes the second inner flange panel 118b and a second outer flange panel 120b rotatably connected to the second inner flange panel 118b at an edge 122b. The second inner flange panel 118b can be connected to the second outer flange panel 120b in a substantially similar manner as the first inner flange panel 118a is connected to the second outer flange panel 120a as described above. In an aspect, the first outer flange panel 120a is rotatably connected to the second outer flange panel 120b. In an aspect, the rotatable connection between the first and second outer flange panels 120a and 120b is defined by a crease line <NUM>. It will be appreciated that the rotatable connection between the first and second outer flange panels 120a and 120b can be defined by alternative structures, such as, multiple crease lines <NUM>, flexible panels, combinations thereof, or still other structures. The first and second inner flange panels 118a and 118b and the first and second outer flange panels 120a and 120b can be configured such that the first inner flange panel 118a and the first outer flange panel 120a are mirror images of the second inner flange panel 118b and the second outer flange panel 120b.

With reference to <FIG>, the rotatable connection between the first and second outer flange panels 120a and 120b can extend at an angle that is angularly offset from the edges 122a and 122b. For example, when the first and second outer flange panels 120a and 120b are aligned such that they both lie on substantially the same plane, the crease line <NUM> can be angularly offset from the edge 122a by an angle A of approximately <NUM> degrees. Similarly, the crease line <NUM> can be angularly offset from the edge 122b by an angle B of approximately <NUM> degrees in a direction opposite the angular offset between the edge 122a and the crease line <NUM>.

The first plurality of flange panels <NUM> can further include a third inner flange panel 118c, a fourth inner flange panel 118d, a third outer flange panel 120c, and a fourth outer flange panel 120d. The third and fourth inner flange panels 118c and 118d and the third and fourth outer flange panels 120c and 120d can be configured substantially similarly to the first and second inner flange panels 118a and 118b and the first and second outer flange panels 120a and 120b, respectively. Each of the third and fourth inner flange panels 118c and 118d can extend from a respective first arbor edge <NUM> of the arbor. Each of the third and fourth outer flange panels 120c and 120d can extend from the respective third and fourth inner flange panels 118c and 118d.

With reference to <FIG>, the first and second outer flange panels 120a and 120b can be configured to connect with the third and fourth outer flange panels 120c and 120d. In an aspect, either or both of the first and second outer flange panels 120a and 120b can include a first connect element <NUM>. Either or both of the third and fourth outer flange panels 120c and 120d can include a second connect element <NUM>. The first and second connect elements <NUM> and <NUM> are configured to connect to one another to selectively retain the first flange <NUM> in the retention configuration. The first and second connect elements <NUM> and <NUM> can include, for example, Velcro connectors, a protrusion and slot connection, snap connection, or other type of connection to selectively connect the first and second outer flange panels 120a and 120b with the third and fourth outer flange panels 120c and 120d.

In an alternative or additional aspect, at least one of the first plurality of inner flange panels <NUM> can be configured to connect with a respective one of the first plurality of outer flange panels <NUM>. The connection between at least one of the first plurality of inner flange panels <NUM> and the respective one of the first plurality of outer flange panels <NUM> can selectively retain the first flange <NUM> in the retention configuration, as further described below.

The first flange <NUM> is configured to transition between the retention configuration (see <FIG> and <FIG>) and the open configuration (see <FIG>, <FIG>, and <FIG>). In the retention configuration, the first and second inner flange panels 118a and 118b extend from the respective first arbor edges <NUM> to a retention height R. In the open configuration, the first and second inner flange panels 118a and 118b extend from the respective first arbor edges <NUM> to an open height. The retention height and the open height extend in a flange direction B from the arbor axis <NUM>. The flange direction B is substantially perpendicular to the arbor axis <NUM>.

The retention height is greater than the open height to allow the roll of material <NUM> to be inserted onto and about the arbor <NUM> (see <FIG>). For example, in the open configuration of the first flange <NUM>, an outer cross-sectional dimension of the first plurality of flange panels <NUM> is less than an inner cross-sectional dimension of the roll of material <NUM>. In the open configuration, at least one of the first inner plurality of flange panels <NUM> is positioned relative to the respective arbor panel to which it is connected at an angle of less than approximately <NUM> degrees. In an example, in a fully open position, each of the first inner plurality of flange panels <NUM> is positioned relative to the respective arbor panel to which it is connected at an angle of approximately <NUM> degrees. In the open configuration, the roll of material <NUM> is removable from the arbor <NUM> in the arbor direction A along the arbor axis <NUM>.

In the retention configuration, the roll of material <NUM> is substantially prevented from removal from the arbor <NUM> along the arbor axis <NUM> by the first and second flanges <NUM> and <NUM> (see <FIG>). For example, in the retention configuration of the first flange <NUM>, an outer cross-sectional dimension of the first plurality of flange panels <NUM> is greater than an inner cross-sectional dimension of the roll of material <NUM>. In the retention configuration, at least one of the first inner plurality of flange panels <NUM> is positioned relative to the respective arbor panel to which it is connected at an angle of approximately <NUM> degrees. It will be appreciated that the roll of material <NUM> can be retained on the arbor <NUM> when at least one of the first inner plurality of flange panels <NUM> is at an angle of less than approximately <NUM> degrees relative to the arbor panel <NUM> to which it is connected if the outer cross-sectional dimension of the first inner plurality of flange panels <NUM> is greater than an inner cross-sectional dimension of the roll of material <NUM>.

The first flange <NUM> can be transitioned from the retention configuration to the open configuration by rotating one or more of the first plurality of flange panels <NUM>. For example, the first and second inner flange panels 118a and 118b can be rotated from approximately <NUM> degrees relative to the respective arbor edge <NUM> to an angle of greater than approximately <NUM> degrees. In an aspect, the first and second inner flange panels 118a and 118b can be rotated to approximately <NUM> degrees. Rotation of the first and second inner flange panels 118a and 118b causes the respective first and second outer flange panels 120a and 120b to rotate about the respective edges 122a and 122b. As the first and second inner flange panels 118a and 118b and the first and second outer flange panels 120a and 120b rotate from <NUM> degrees toward <NUM> degrees relative to the arbor <NUM>, the first flange <NUM> extends axial outward from the arbor <NUM> in the arbor direction A. When the first and second inner flange panels 118a and 118b reach the open height, the roll of material can be positioned on the arbor <NUM> by moving the roll of material along the arbor axis <NUM>.

To transition the first flange from the open configuration to the retention configuration, the first and second inner flange panels 118a and 118b are rotated toward the <NUM> degree position relative to the respective arbor panel <NUM>. As the first and second inner flange panels 118a and 118b and the first and second outer flange panels 120a and 120b rotate toward <NUM> degrees relative to the arbor <NUM>, the first flange <NUM> retracts axially inward toward the arbor <NUM> in a direction opposite the arbor direction A. After the first and second inner flange panels 118a and 118b reach the retention height H, the roll of material <NUM> is retained on the arbor <NUM>.

The first flange <NUM> can be selectively retained in the retention configuration by connected the first connect element <NUM> to the second connect element <NUM>. In an aspect, in the retention configuration of the first flange <NUM>, a surface of the first outer flange panel 120a abuts against a surface of the first inner flange panel 118a, and a surface of the second outer flange panel 120b abuts against a surface of the second inner flange panel 118b. One or both of the sets of abutting surfaces of the first inner and outer flange panels 118a and 120a and the second inner and outer flange panels 118b and 120b can include connect elements (see e.g. <FIG> - snap feature) to selectively connect the abutting surfaces together. The selective connection between the abutting surfaces can selectively retain the first flange <NUM> in the retention configuration.

It will be appreciated that the third and fourth inner flange panels 118c and 118d and the third and fourth outer flange panels 120c and 120d can be moved and/or transitioned substantially similarly as the first and second inner flange panels 118a and 118b and the first and second outer flange panels 120a and 120b to transition the first flange <NUM> between the retention configuration and the open configuration.

It will be appreciated that the second flange <NUM> can be configured substantially similarly to the first flange <NUM>. For example, the second flange <NUM> can include a second plurality of flange panels <NUM>. The second plurality of flange panels <NUM> can transition the second flange <NUM> between a retention configuration to retain the roll of material <NUM> on the arbor <NUM>, and an open configuration to allow the arbor <NUM> to receive the roll of material <NUM> and to allow the roll of material <NUM> to be removed from the arbor <NUM>. It will be appreciated that the first and second flanges <NUM> and <NUM> can be configured differently from one another. For example, the second flange <NUM> can be configured such that the second flange is retained or locked in the retention position. To receive and remove the roll of material <NUM> from the arbor <NUM>, the first flange <NUM> is selectively transitioned between the retention and open configurations.

The precise appearance and structure defined by the spool <NUM> can be modified without departing from the scope of the present invention as claimed. For example, the connect elements <NUM> and <NUM> can be located on different panels of either of the first and second flanges <NUM> and <NUM>. In another alternative, the spool <NUM> could have fewer or more inner panels and/or fewer or more outer panels configured to transition between retention and open configurations. In another alternative aspect, each of the outer flange panels <NUM> can be connected to each adjacent outer flange panel <NUM>.

<FIG> illustrate a spool <NUM>, according to an alternative aspect of this disclosure. It will be appreciated that the spool <NUM> can be transitioned, aligned, and configured in a substantially similar manner as the spool <NUM> described herein. The spool <NUM> includes an arbor <NUM>, a first flange <NUM>, and a second flange <NUM>. The arbor member <NUM> and the first and second flanges <NUM> and <NUM> can be integrally formed as a single unitary piece. For example, the first and/or the second flange <NUM> and <NUM> can transition between an open position and a retention position without removing either the first and the second flange <NUM> and <NUM> from the arbor <NUM>. The spool <NUM> can comprise a paperboard material.

With reference to <FIG>, a first outer panel 120a of a plurality of first flange panels <NUM> includes a first connect element <NUM>. The first connect element <NUM> defines a first aperture <NUM> that extends therethrough. A third outer panel 120c of the plurality of the first flange panels <NUM> includes a second connect element <NUM> that defines a second aperture <NUM> that extends therethrough. In the retention configuration of the first flange <NUM>, the first aperture <NUM> can substantially align with the second aperture <NUM> along an arbor axis <NUM>. In an aspect, the spool <NUM> can include a dowel member (not shown). The dowel member can be configured to extend through the arbor <NUM>, the first aperture <NUM>, and the second aperture <NUM> along the arbor axis <NUM> when the first flange <NUM> is in the retention configuration. In an aspect, the second flange <NUM> can be configured substantially similarly to the first flange <NUM>. The dowel member can further extend through first and second apertures (not shown) of the second flange <NUM>. The dowel member can allow the spool to rotate about the arbor axis <NUM> such that a roll of material <NUM> can be wound about the arbor <NUM> by rotating the spool <NUM> about the arbor axis <NUM> in a coil direction. Similarly, the roll of material <NUM> can be unwound from the arbor <NUM> by rotating the spool <NUM> about the arbor axis <NUM> in a direction opposite the coil direction.

<FIG> illustrate a spool <NUM>, according to an alternative aspect of this disclosure. It will be appreciated that the spool <NUM> can be transitioned, aligned, and configured in a substantially similar manner as either of the spools <NUM> and <NUM> described herein. The spool <NUM> includes an arbor <NUM>, a first flange <NUM>, and a second flange <NUM>.

The arbor <NUM> includes a plurality of arbor panels <NUM>. Each of the arbor panels <NUM> includes a substantially triangular shape. Each of the arbor panels <NUM> is connected to each adjacent arbor panel <NUM> in series about an arbor axis <NUM>. In an aspect, every other arbor panel <NUM> spaced about the arbor axis <NUM> includes a first arbor edge connected to the first flange <NUM>. Each of the other every other arbor panels <NUM> spaced about the arbor axis <NUM> includes a second arbor edge that is connected to the second flange <NUM>. For example, a first arbor panel 310a and a third arbor panel 310c of the plurality of arbor panels <NUM> each include a first arbor edge. The first arbor edge of both the first and third arbor panels 310a and 310c is rotatably connected to a respective flange panel of a plurality of flange panels <NUM>. A second arbor panel 310b of the plurality of arbor panels <NUM> is positioned circumferentially between the first and third arbor panels 310a and 310c. The second arbor panel 310b includes a second arbor edge that is connected to the second flange <NUM>. The configuration of the plurality of arbor panels <NUM> can circumferentially offset the first flange <NUM> from the second flange <NUM> when viewed along the arbor axis <NUM> (see <FIG>).

<FIG> illustrate a spool <NUM>, according to an alternative aspect of this disclosure. It will be appreciated that the spool <NUM> can be transitioned, aligned, and configured in a substantially similar manner as any of the spools <NUM>, <NUM>, and <NUM> described herein. The spool <NUM> includes an arbor <NUM>, a first flange <NUM>, and a second flange <NUM> constructed of a single piece of paperboard material.

<FIG> illustrates a top view of a spool <NUM> in an unassembled configuration, according to an aspect of this disclosure. It will be appreciated that the spool <NUM> can be transitioned, aligned, and configured in a substantially similar manner as any of the spools <NUM>, <NUM>, <NUM>, and <NUM> described herein. The spool <NUM> comprises a one-piece paperboard blank <NUM>. The blank <NUM> can be assembled to form an arbor <NUM>, a first flange <NUM>, and a second flange <NUM>.

The method of assembling the spool <NUM> includes forming crease lines <NUM> in the blank <NUM> between each of the plurality of arbor panels <NUM>. Each of the crease lines <NUM> can allow each arbor panel <NUM> to rotate relative to an adjacent arbor panel <NUM>. Crease lines <NUM> can be formed between each of the plurality of arbor panels <NUM> and respective inner flange panels of a plurality of inner flange panels <NUM>. Each of the crease lines <NUM> can allow each of the plurality of inner flange panels <NUM> to rotate relative to a respective one of the plurality of arbor panels <NUM>. Crease lines <NUM> can be formed between each of the plurality of inner flange panels <NUM> and respective outer flange panels of a plurality of outer flange panels <NUM>. Each of the crease lines <NUM> can allow each of the plurality of outer flange panels <NUM> to rotate relative to a respective one of the plurality of inner flange panels <NUM>. A crease line (see e.g. crease line <NUM> in <FIG>) can be formed between adjacent outer flange panels <NUM> to allow adjacent outer flange panels <NUM> to rotate relative to each other. After the crease lines are formed in the blank <NUM>, a first arbor panel 510a of a plurality of arbor panels <NUM> can be connected to a second arbor panel 510b of the plurality of arbor panels <NUM>. After connecting the first arbor panel 510a to the second arbor panel 510b, the spool <NUM> is transitionable between the open configuration and the retention configuration.

<FIG> illustrate a spool <NUM>, according to another alternative aspect of this disclosure. Spool <NUM> generally includes a barrel <NUM> (e.g. an arbor), a fixed flange <NUM>, and a collapsible flange <NUM>. Collapsible flange <NUM> can be configured in a collapsed condition as shown in <FIG> which allows a coiled item to be slid over flange <NUM> onto barrel <NUM>. The coiled item can be a coil of thread, cord, wire, rope, or line. Fishing line such as fly fishing line can be stored on spool <NUM>. Spool <NUM> defines a central opening <NUM> that allows it be rotatable mounted or stored on a hanger. In an alternative aspect, the spool <NUM> can include multiple collapsible flanges. For example, both of the fixed flange <NUM> and the collapsible flange <NUM> can be configured to transition to a collapsed condition to receive a coiled item to be slid over the respective flange.

Spool <NUM> can be folded into the intermediate condition of <FIG> and then the erected position of FIGS. <NUM>-<NUM> from the flat condition of <FIG>. The flat condition of <FIG> can be cut from a flat piece of material such as a paper, a paperboard, or a polymer board. In the exemplary configuration, the foldable material is a <NUM> Solid Bleached Sulphate (SBS) paperboard. The locations where the material is folded can be scored, cut through, or indented. Adhesive is used to hold portions together as marked with wavy lines in <FIG> and as marked. It will be appreciated that the spool <NUM> can be held together in other ways than adhesive (e.g. snap-fits, interference fits, mechanical interlocking, etc.). Spool <NUM> can be made from a recyclable paper or polymer material. In other configurations, the elements of spool <NUM> can be formed separated and joined.

Spool <NUM> can be erected from the flat condition shown in <FIG> into an intermediate condition of <FIG> wherein all of the connections (e.g. adhesive connections) have been made but barrel <NUM> has not been completed. In this condition, the walls that used to form barrel <NUM> are disposed as two parallel members that allows collapsible flange <NUM> to pivot down until portions of its inner surface engage portions of the inner surface of fixed flange <NUM>. In this condition, spool <NUM> is substantially flat which is desired for storage and shipping. From this intermediate condition, the user finishes the erection of spool <NUM> by pivoting collapsible flange <NUM> up away from fixed flange <NUM> until the walls that are used to form barrel <NUM> are substantially perpendicular to flanges <NUM> and <NUM>. The barrel half walls are folded toward each other and their ends are interlocked to complete the erection of spool <NUM>.

Once in the erected condition, spool <NUM> can be loaded with a coiled item either by winding the item around barrel or by sliding the coiled item over collapsible flange <NUM>. Some coiled items such as fly fishing line are coiled during manufacturing and it is not desirable to uncoil the line from its condition and rewind it onto barrel <NUM>. As such, collapsible flange <NUM> can be changed to its collapsed condition shown in <FIG>, which allows the coiled item to be slid over collapsed flange <NUM> and onto barrel <NUM>. When in the collapsed condition, flange <NUM> has a cross section (taken perpendicular to the axis of rotation of spool <NUM>) that less than or equal to the cross section of barrel <NUM>. Collapsed flange <NUM> may be tapered down along its length to provide for easy loading of coiled items. After the coiled item is loaded onto barrel <NUM>, collapsible flange <NUM> is returned to the erected condition shown in <FIG> and <FIG> to retain the coiled item on spool <NUM>.

Barrel <NUM> includes four walls <NUM>, <NUM>, <NUM>, and <NUM> with walls <NUM> and <NUM> being formed by barrel half walls <NUM> that have mechanically interlocking end portions <NUM>. In some configurations, a user can optionally use adhesive to secure the interlocking end portions <NUM>. The interlocking end portions <NUM> can include, for example, corresponding snap-fits, interference fits, or other corresponding connection or interlocking portions. Walls <NUM> and <NUM> and parallel and hinged at or to flanges <NUM> and <NUM>. These hinges allow flange <NUM> and barrel <NUM> to pivot down to the substantially flat condition when they are in the intermediate condition.

Fixed flange <NUM> includes two main layers and an attachment flange <NUM> used to anchor barrel wall <NUM>. Attachment flange is adhered to a portion of the inner surface of flange <NUM> inside barrel <NUM>. The two main layers of flange <NUM> include an outer panel <NUM> (defining a portion of opening <NUM>) and first <NUM> and second <NUM> inner panels which are folded against and adhered to outer panel <NUM>. First inner panel overlaps and defines a portion of opening <NUM>. Barrel wall <NUM> is connected to an inner end of second inner panel <NUM>. Flange <NUM> can be octagonal.

Collapsible flange <NUM> includes two main layers defined by an outer panel <NUM> and first <NUM> and second <NUM> inner panels which are adhered to outer panel. First inner panel <NUM> is connected to the top of barrel wall <NUM> and second inner panel <NUM> is connected to the top of barrel wall <NUM>.

Collapsible flange <NUM> can include a rectangular or square central portion <NUM> from which four tapered subpanels <NUM> extend. It will be appreciated that fewer or more subpanels <NUM> can extend from the central portion <NUM>. <FIG> and <FIG> illustrate the tapered sides of subpanels <NUM>. The tapered sides of subpanels <NUM> can facilitate the insertion of the fishing line when the spool <NUM> is in the collapsed condition. Folding corner panels <NUM> connect the later edges of subpanels <NUM> and define a corner relief. When flange <NUM> is collapsed, folding corner panels <NUM> are folded inward as shown in <FIG> such that subpanels are disposed at or within the cross sectional perimeter of barrel <NUM>. The folding corner panels can minimize tangling, bending, or other damage to the filament positioned about the barrel <NUM>.

Claim 1:
A spool (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) for supporting a roll of material (<NUM>, <NUM>), the spool comprising:
An arbor (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) that extends about an arbor axis (<NUM>, <NUM>, <NUM>), the arbor including a plurality of arbor panels (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) connected to each other and spaced about the arbor axis, wherein first (110a, 310a, 510a) and second arbor panels (110b, 310c, 510b) of the plurality of arbor panels each include a first arbor edge (<NUM>), and wherein a third arbor panel (110c, 310b) of the plurality of arbor panels includes a second arbor edge (<NUM>), wherein the first arbor edges of the first and second arbor panels are spaced from the second arbor edge of the third panel in an arbor direction, the arbor direction being substantially parallel to the arbor axis;
a first flange (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) that includes a first plurality of flange panels (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein a first flange panel (118a) of the first plurality of flange panels is rotatably connected to the first arbor edge of the first arbor panel, and wherein a second flange panel (118b) of the first plurality of flange panels is rotatably connected to the first arbor edge of the second arbor panel; and
a second flange (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) connected to the second arbor edge of the third arbor panel, and
characterized in that the first flange is configured to transition between a retention configuration and an open configuration, wherein in the retention configuration, the first and second flange panels of the first plurality of flange panels extend from the respective first arbor edges to a retention height (R), and wherein in the open configuration, the first and second flange panels of the first plurality of flange panels extend from the respective first arbor edges to an open height, the retention height and the open height extending in a flange direction (B), the flange direction being substantially perpendicular to the arbor axis, and
wherein the retention height is greater than the open height, wherein in the retention configuration, the roll of material is substantially prevented from removal from the arbor along the arbor axis by the first and second flanges, and wherein in the open configuration, the roll of material is removable from the arbor in the arbor direction.