Patent ID: 12201102

DETAILED DESCRIPTION

The present disclosure describes a fishing reel, such as a lever drag fishing reel, with improved cast control features for reducing backlash and increasing performance of the fishing reel. A lever drag fishing reel, as opposed to a star drag fishing reel, includes a lever that allows for relatively gradual adjustment of an amount of drag applied to a spool by known amounts. A star drag fishing reel, on the other hand, provides a single switch to engage or disengage the drag mechanism as well as a drag lever with a plurality of arms extending therefrom that allows for adjustment of the amount of drag while the drag is applied to the spool. The cast control mechanism disclosed herein may be specifically designed for use with a lever drag reel to improve operation of the fishing reel by reducing the likelihood of backlash occurring while casting. This allows an angler to cast farther and waste less time untangling fishing line as a result of backlashes. Additionally, the cast control mechanism disclosed herein is designed to reduce a total weight of the fishing reel relative to alternative cast control designs, in turn allowing anglers to spend more time fishing with the reel before becoming tired.

In particular and referring toFIGS.1,2,3,4,5, and6(FIGS.1-6), a fishing reel100may be designed to have a cast control system or mechanism101. The fishing reel100may include a casing102(or housing) which houses at least a portion of components of the fishing reel100. The casing102may include external components, in which case a portion of such components are exposed to an environment of the fishing reel100, may include internal components which lack exposure to the environment of the fishing reel100, or may include external components and internal components. In particular, the casing102may include a main housing104. The casing102may also include a shaft housing105which may at least partially house a main shaft148. At least a portion of a spool assembly108may also be considered a portion of the casing102. In some embodiments, at least one of the casing102, the main housing104, or the shaft housing105may include multiple components coupled together. For example, the main housing104may include multiple pieces coupled together to form the main housing104. In some embodiments, at least one of the casing102, the main housing104, or the shaft housing105may be formed integral or monolithic. In some embodiments, two or more of the casing, the main housing104, and the shaft housing105may be formed integrally or monolithic with each other.

The main housing104may be made from any material such as a metal (e.g., a corrosion-resistant aluminum, such as aircraft grade aluminum), a plastic, another polymer, or the like. Additional components of the fishing reel100(e.g., any components such as a spool110, a spool cover112, a handle150, or the like) may likewise be made, or may include, any materials such as metals, plastics, polymers, or the like. All components need not include the same materials. For example, the main housing104may include aircraft grade aluminum, a spool shaft136may include a steel, the handle150may include a plastic, and the like. Likewise, a single component may include multiple materials. For example, the handle150may include a metal shaft with a plastic handle wrapped in a rubber.

The main housing104may have an inner surface106facing radially inward (i.e., towards an axis A-A′) and an outer surface107which may be exposed to an environment of the fishing reel100. In some embodiments, the outer surface107may be opposite the inner surface106.

The fishing reel100may also include a spool assembly108. The spool assembly108may include any one or more components that at least partially form a spool portion of the fishing reel100. For example, the spool assembly108may include a spool110onto which fishing line becomes wound and unwound. The spool110(and, in some embodiments, the entire spool assembly108) may rotate along with a spool shaft136about an axis A-A′ in a first direction to wind line onto the spool110, and may rotate along with the spool shaft136in a second direction about the axis A-A′ to unwind line from the spool110. At least one of the spool assembly108or the spool110may be positioned relatively near the main housing104and may at least partially enclose a portion of the fishing reel between the main housing104and the spool110(or another portion of the spool assembly108). The spool110may rotate relative to the main housing104(and the casing102). In that regard, the casing102and/or the main housing104may remain stationary relative to the axis A-A′ while the spool110(and, in some embodiments, additional components of the spool assembly) rotates about the axis A-A′.

The spool assembly108may also include a spool cover112. In some embodiments the spool cover112may be coupled to the spool110. For example, the spool cover112may include a plurality of apertures134exposed to the spool110and fasteners132may extend through the apertures134and fasten the spool cover112to the spool110. In some embodiments, although not shown herein, the spool cover112may also or instead be coupled to the spool shaft136. In some embodiments, the various components (e.g., between the spool110and spool cover112) may be coupled together using any means such as fasteners, press-fit connections, an interference fit, adhesive, or the like. In some embodiments, the spool cover112may also rotate with the spool110and the spool shaft136. In some embodiments, the spool110and the spool cover112may rotate together while the shaft136is allowed to float (i.e., not rotate) relative to the spool110and spool cover112. In some embodiments, the spool cover112may be formed integrally (i.e., monolithically) with at least one of the spool110, the spool shaft136, or the like.

The spool cover112may include a clicker portion114and a spool portion116. The clicker portion114and the spool portion116may be formed monolithic with each other, may be formed separately and coupled together, or the like. The spool portion116may have a greater diameter than the clicker portion114, as the clicker portion114may be in contact with and surround the spool shaft136, and the spool portion116may be in contact with (and have a similar diameter as) an outer portion of the spool110. The clicker portion114may be utilized as part of a clicking mechanism118which may also include: a button120to engage and disengage the clicking features, a plurality of protrusions122(e.g., radially-extending protrusions, although axial protrusions are also possible without departing from the scope of the present disclosure) coupled to the clicker portion114, and an arm124coupled to the main housing104(i.e., which may remain stationary relative to the rotating portion of the fishing reel100). The button120may have a first position in which the arm124may be spaced from the protrusions122such that the arm124and protrusions122fail to make contact in response to rotation of the clicker portion114, and a second position in which the arm124contacts the protrusions122as the clicker portion114rotates relative to the arm124. In response to the button120being in the second position, the protrusions122may contact the arm124as they pass by the arm124during rotation of the protrusions122, which may result in a “click” or “pop” noise. Such noise may alert an angler to a hookup with a fish. Engagement of the clicking mechanism118(i.e., when the button120is in the second position) may provide other advantages such as adding resistance to the spool110when the fishing reel100is in free spool. In some embodiments, other clicking mechanisms are contemplated such as an arm located on the clicker portion114and protrusions coupled to the main housing104(e.g., the arm may rotate about an axis and the protrusions may remain stationary relative to the arm), the arm124remaining coupled to the main housing104and protrusions coupled to a different structure than the spool cover112, or the like.

The spool portion116of the spool cover112may be coupled to the spool110. In that regard, the fasteners132may extend through the spool portion116and couple the spool portion116to the spool110. In some embodiments, the spool portion116may be coupled to the spool110in any additional or alternative manner. For example, the spool portion116may not be directly coupled to the spool110, and the clicker portion114may be coupled to the spool shaft136to cause the spool cover112to rotate with the spool110(in embodiments in which the spool shaft136rotates with the spool110). The spool portion116may, together with the spool110, define a cavity therebetween. Inclusion of the cavity (rather than solid material) may reduce a weight of the fishing reel100, thus allowing an angler more opportunity to fish before becoming tired.

The spool shaft136may be centered along, and extend parallel to, the axis A-A′. As referenced above, the spool shaft136may rotate about the axis A-A′ relative to stationary components of the fishing reel100(such as the main housing104). As indicated above, the spool110may rotate relative to the spool shaft136when the fishing reel100is in free spool (i.e., the spool shaft136may float relative to the spool110. As the fishing reel is placed in gear and an angler cranks the handle150(and as further described below), the spool shaft136(and spool110) may rotate in a second direction, causing line to wind around the spool110.

As mentioned above, the fishing reel100may be a lever drag fishing reel. In that regard, the fishing reel100may include a lever138(not shown in detail herein). The lever138may be actuated in a first direction relative to the main housing104(e.g., into the page as shown inFIG.1) to engage and to increase an amount of drag applied to the spool110(i.e., to place the fishing reel100in gear), and may be actuated in a second direction relative to the main housing104(e.g., out of the page as shown inFIG.1) to reduce the amount of drag and to disengage the drag from the spool110. The lever138may be rotated between any of a plurality of locations which each correspond to a particular amount of drag. The fishing reel100may also include a drag adjustment control mechanism139, such as a knob or dial. The drag adjustment control mechanism139may be rotated clockwise or counterclockwise to increase and decrease an amount of drag that is applied to the spool110in response to engagement of the drag mechanism. For example, the drag may apply a certain force (e.g., 5 pounds) in response to the lever138being located in a first position. After adjusting the drag adjustment control mechanism139, the drag may apply a different force (e.g., 7 pounds) in response to the drag lever138being located in the first position.

The fishing reel100may include a plurality of drag surfaces as part of the drag mechanism to apply drag to the spool110. For example, the fishing reel100may include a first drag surface140(which may be formed on, or coupled to, the spool110or spool shaft136and may rotate with the spool110) and a second drag surface142(which may be formed as part of, or coupled to, the casing102and may remain stationary relative to the spool110). In some embodiments, the first and second drag surfaces140,142may be located on a first end of the spool110, and the fishing reel100may include additional drag surfaces146which may be located on a second end of the spool110. In some embodiments, the additional drag surfaces146may be a mirror image of the first and second drag surfaces140,142. Inclusion of the additional drag surfaces146may increase an amount of drag which may be applied to the spool110or the spool shaft136, thus making the fishing reel100capable of fighting larger fish than would be possible if the fishing reel included only the first and second drag surfaces140,142. That is, the drag surfaces146on the second end of the spool110may increase an amount of drag applied by the fishing reel relative to inclusion of only the first and second drag surfaces140,142. Each of the drag surfaces140,142,146may include friction surfaces, such as metal (which may or may not have a rough surface to increase friction), a polymer with carbon fiber to increase friction applied thereby, both, or any other material or combination of materials. For example, the first drag surface140may include a polymer with carbon fibers and the second drag surface142may include a metal (e.g., steel or aluminum). Additionally, the first drag surface140(and any additional or alternative drag surfaces) may include multiple surfaces thereon. For example, a drag disk may be located axially between two additional drag surfaces, and each surface of the drag disk may include a friction surface for engaging with each additional drag surface. Each side of the spool110may include any quantity of drag surfaces. In some embodiments, optimum performance may be obtained by having similar drag surfaces on both sides of the spool110.

As shown inFIG.1, the first drag surface140may include a washer and may be coupled to the spool110, for example, using protrusions (e.g., cogs) that interface with apertures or protrusions of the spool110. That is, a surface144of the first drag surface140may be radially coupled to the spool110. In that regard, the interface between the first drag surface140and the spool110resists rotation of the first drag surface140relative to the spool110. In some embodiments, the first drag surface140may be a friction surface formed on a surface of the spool110rather than a separate washer. The second drag surface142may be coupled (e.g., rotatably coupled) to the main housing104. For example, the second drag surface142may include a washer that is coupled to the main housing104, for example, using an adhesive, fasteners, protrusions (e.g., cogs), or the like. In that regard, the second drag surface142may rotate relative to the first drag surface140. In some embodiments, the second drag surface142may be a friction surface formed on a surface of the main housing104rather than a separate washer. Friction may occur between the first drag surface140and the second drag surface142in response to rotation of the spool110relative to the casing102. Any quantity and configuration of drag surfaces is contemplated and covered within the scope of the present disclosure.

The fishing reel100may include a plurality of bearings that reduce friction between parts for which relative motion occurs. For example, a bearing156may reduce friction between the spool shaft136and the main housing104. As another example, bearings may exist between the spool shaft136and the spool110to reduce friction therebetween when the spool shaft136is disengaged from the spool110. Any additional or alternative bearings may be included without departing from the scope of the present disclosure.

The fishing reel100may also include a main shaft148. The main shaft148may be coupled (e.g., rotatably coupled) to a handle150(e.g., a direct connection via fasteners, cogs, adhesive, or the like; indirectly coupled via gearing; or the like). The main shaft148and handle150may rotate about a second axis B-B′ which may or may not be parallel to the spool shaft136. Due to the interface between the handle150and the main shaft148, rotation of the handle150by an angler in turn rotates the main shaft148.

The fishing reel100may also include a main gear152rotatably coupled to the main shaft148either via gearing, via a direct connection, or the like. The fishing reel100may also include a drag gear154that is rotatably coupled to the spool shaft136either via gearing, via a direct connection, or the like. The main gear152is engageable with the drag gear154. For example, the main gear152and the drag gear154may each include cogs or other features that facilitate rotational engagement with one another. In that regard and in response to engagement between the main gear152and the drag gear154, rotation of the handle150may rotate the main shaft148, which in turn rotates the main gear152, which rotates the drag gear154(if the amount of force applied to the spool110is less than or equal to the set amount of drag), which rotates the spool shaft136and the spool110. In some embodiments, the main gear152may remain engaged with the drag gear154.

The fishing reel100may also include a cam and cam track or other axially-actuatable feature positioned adjacent or proximal to the spool shaft136. The cam or cam track may be coupled to the lever138such that actuation of the lever138in a first direction (e.g., into the page as shown inFIG.1) actuates the cam in a first axial direction (e.g., to the left as shown inFIG.1), and actuation of the lever138in a second direction (e.g., out of the page) actuates the cam in a second axial direction (e.g., to the right). Actuation of the lever138all the way in the second direction may in turn move the spool shaft136to the left, thus separating the second friction surface142from the first friction surface140such that no friction exists therebetween. This lack of contact between the friction surfaces140,142allows the spool110to rotate freely relative to the main housing104.

Actuation of the lever138in the first direction urges the second friction surface142towards the first friction surface140, resulting in contact therebetween. Thus in response to rotation of the spool110when the lever138is actuated in the first direction, the friction applied to the first friction surface140by the second friction surface142brakes or otherwise reduces rotation of the spool110. This is because the first drag surface140is coupled to the spool110and the second drag surface142is coupled to the main housing104. Thus, the friction between the drag surfaces140,142reduces the ability of the spool110to rotate freely relative to the main housing104. As the lever138is urged further in the first direction, the drag surfaces140,142are urged closer together, thus increasing friction therebetween, thus increasing an amount of drag applied to the spool110. The drag adjustment control mechanism139may adjust how much axial force is applied to the drag surfaces140,142(i.e., a distance between the drag surfaces140,142), such that actuation of the lever138increases or decreases braking force at each location along the path of the lever138.

As discussed above, the fishing reel100includes a cast control mechanism101to reduce backlash and increase performance of the fishing reel100. The cast control mechanism101may include portions of the casing102, the spool assembly108, and at least one body130. For example, the cast control mechanism101may include an inner surface106of the casing102(e.g., the inner surface106may be defined by the main housing104), an outer surface126of the spool assembly108(e.g., the outer surface126may be defined by the spool cover112), and the at least one body130. In some embodiments, the outer surface126may be located radially inward relative to the inner surface106of the casing102. However, one skilled in the art will realize that the surfaces of the cast control mechanism101may be located on any additional or alternative components of the fishing reel100. In some embodiments, the at least one body130may have a cylindrical shape, however, other shapes (e.g., triangular prism, rectangular prism, or the like) are also within the scope of the present disclosure.

In the embodiment illustrated inFIGS.1-6, the cast control mechanism101may include the inner surface106defined by the main housing104, the outer surface126defined by the spool cover112, and a plurality of bodies130. In particular, the inner surface106of the main housing104may at least partially face the outer surface126of the spool cover112. The outer surface126of the spool cover112may define at least one pocket128that has an opening at least partially facing the inner surface106of the main housing104. The at least one pocket128may extend radially relative to the outer surface107. The at least one pocket128may include an elongated aperture or void at least partially defined by the outer surface126(or by another component). In some embodiments, the outer surface126may be angled relative to the inner surface106of the casing102(as shown inFIG.1) and, in some embodiments, the outer surface126may extend substantially parallel to the inner surface106(i.e., the outer surface126may directly face the inner surface106). The angle may be irrelevant to operation of the cast control mechanism101so long as the bodies130are sufficiently retained within the pockets128and between the outer surface126and the inner surface106during operation.

In some embodiments, the cast control mechanism may be located between any two surfaces of the fishing reel100so long as one surface rotates relative to the other surface. In that regard, pockets may be formed in any outward- or inward-facing surface of the fishing reel, bodies may be located within the pockets, and the pockets may at least partially face another inward or outward-facing surface (which is opposite the first surface) so long as one of the first surface or the second surface rotates relative to the other.

The pocket(s)128may be sufficiently large that the at least one body130may be received by the pocket128(i.e., a circumference of the pocket128may be equal to or greater than, and may have a shape that corresponds to, a circumference of the at least one body130). In some embodiments, the dimensions of the pocket128may be sufficiently similar to the dimensions of the body130such that the body130may move within the pocket128(e.g., may move radially inward and outward but relatively restricted from movement in non-radial directions relative to the pocket128) but remains in the pocket128when the fishing reel100is assembled (as shown inFIG.1). Similarly, a length of the body130, the length of the pocket128, and the spacing between the outer surface126of the spool cover112and the inner surface106of the main housing104may be designed such that the body130may move within the pocket128between a first position in which the body130fails to contact the inner surface106, and a second position in which the body130contacts the inner surface106. The cast control mechanism101may also be designed such that the body130is retained within the pocket128and between the pocket128and the inner surface106of the main housing104regardless of the position of the body130within the pocket. That is, the length of the pockets128, the length of the bodies130, and a distance between the outer surface126of the spool cover112and the inner surface106of the casing102may be designed such that the bodies130are unlikely or unable to become dislodged from the pockets128while the casing102is assembled around the spool cover112. Stated differently, a distance between an outer end of the pocket128and the inner surface106may be less than a total length of the body130such that the body130remains in the pocket while the fishing reel100is assembled.

In some embodiments, the pockets128may be evenly spaced circumferentially about the spool cover112. That is, a distance between each adjacent pocket128along the circumference of the spool cover112may be the same. Such even spacing provides relatively smooth operation of the fishing reel100and cast control mechanism101and reduces imbalance within the fishing reel100. In some embodiments, the pockets128may be spaced other than evenly. That is, for example, a greater quantity of pockets128may be located on one hemisphere of the spool cover112than on an opposing hemisphere of the spool cover112. Experiments have shown that even spacing of the pockets128is unnecessary to achieve desirable performance.

In some embodiments, the cast control mechanism101may include any quantity of pockets128and bodies130, and a quantity of pockets128may correspond to a quantity of bodies130(such that each body130corresponds to one pocket128). For example, the cast control mechanism101may include between 1 and 16 of each of the bodies130and pockets128, between 2 and 14, between 4 and 12, between 6 and 10, about 8, or the like. The pockets128may be evenly spaced around the outer surface126of the spool cover112, and each body130may be received by a respective pocket128. As mentioned above, installation of the spool cover112within the main housing104may cause the bodies130to remain within the pockets128via the inner surface106of the main housing104.

As the fishing reel100is used to cast a lure or bait, the spool110rotates to allow fishing line to unwind from the spool110. This rotation of the spool110in turn rotates the spool cover112. The centrifugal force of this rotation of the spool cover112urges the bodies130outward towards the inner surface106of the casing102(e.g., the main housing104). In some embodiments, the bodies130or the spool cover112may include a magnetic material to attract the bodies130towards the spool cover112(e.g., urging the bodies130radially inward). However, some embodiments lack such magnetic features. In embodiments in which the bodies130are attracted to the spool cover112(i.e., radially inward via magnetic force as a result of magnetic material in at least one of the bodies130or the spool cover112), the centrifugal force may overcome the attraction of the bodies130to the spool cover112such that the bodies may contact the inner surface106. In some embodiments, the force of this urging of the bodies130towards the inner surface106is based on an angular velocity of the spool shaft136such that a greater angular velocity increases the force between the bodies130and the inner surface106, and a reduced angular velocity decreases this force. Rotation of the spool cover112(and thus the bodies130) relative to the inner surface106while the bodies130are in contact with the inner surface106generates friction between the bodies130and the inner surface106(and the friction may be increased or decreased based on the force, which is based on the angular velocity). This friction slows rotation of (i.e., brakes) the spool cover112and, thus, the spool110. When the lure or bait hits the water, line may stop being removed from the spool110(or at least line may not be pulled any further by the lure or bait). This may occasionally result in rotation of the spool110while no line is being removed from the spool110, which may cause the line to become loose and wrap around the spool110, undesirably causing backlash which may tangle the fishing line. The braking force applied to the spool110by the friction between the bodies130and the inner surface106reduces this unwanted continued rotation of the spool110, reducing the likelihood of experiencing backlash and, if backlash is experienced, reducing the severity of such backlash.

The design of the cast control mechanism101of the fishing reel100shown herein provides additional advantages such as allowing access to the cast control mechanism101in order to replace the bodies130with bodies of a different mass (to increase or decrease braking of the fishing reel100), to replace damaged bodies130, to remove the bodies130to operate the reel without the cast control mechanism101, or the like. In that regard, the main housing104may be removed from the fishing reel100to expose the spool cover112, thus exposing the pockets128and the bodies130. The bodies130may be removed from the pockets128and potentially replaced with different bodies130.

In some embodiments, use of magnetic forces (e.g., by adding magnets in at least one of the spool cover112or the bodies130) may be desirable as it can cause the bodies130to remain in the pockets128regardless of whether the main housing104is installed or not. Likewise, this magnetic force may resist contact between the bodies130and the inner surface106of the casing102unless the angular velocity of the spool cover112is sufficiently great so as to cause the centrifugal force to overcome the magnetic force. This reduced contact between the bodies130and the inner surface106may allow the fishing reel100to cast farther than if the bodies130are allowed to freely contact the inner surface106.

The cast control mechanism101disclosed herein provides additional benefits and advantages. The cast control mechanism101may reduce a total weight of the fishing reel100relative to alternative cast control mechanisms by taking advantage of structures within the fishing reel100. For example, the fishing reel100makes use of a casing to enclose various components of the fishing reel for protection from the elements and has an inner surface that may be used as part of the cast control mechanism101. In addition, use of the spool cover112provides multiple functions such as operating as part of the clicking mechanism118and functioning to cover the spool110, thus allowing the cast control mechanism101to be functional by only adding the bodies130. This reduces a total weight of the fishing reel100relative to alternative cast control designs, allowing an angler to spend more time fishing before becoming tired.

Where used throughout the specification and the claims, “at least one of A or B” includes “A” only, “B” only, or “A and B.” Exemplary embodiments of the methods/systems have been disclosed in an illustrative style. Accordingly, the terminology employed throughout should be read in a non-limiting manner. Although minor modifications to the teachings herein will occur to those well versed in the art, it shall be understood that what is intended to be circumscribed within the scope of the patent warranted hereon are all such embodiments that reasonably fall within the scope of the advancement to the art hereby contributed, and that that scope shall not be restricted, except in light of the appended claims and their equivalents.