Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/269,734, filed Nov. 12, 2008, (now issued as U.S. Pat. No. 7,810,751 to Caamano et al.) which is a continuation of U.S. patent application Ser. No. 11/420,164, filed May 24, 2006 (now issued as U.S. Pat. No. 7,533,843 to Caamaño et al.), which claims the benefit of U.S. Provisional Patent Application No. 60/685,637 filed May 27, 2005, and U.S. Provisional Patent Application No. 60/772,455 filed Feb. 10, 2006. The entire contents of all four of said priority applications (to which the present application claims priority) are incorporated herein by reference and should be considered a part of this specification. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to reels for spooling linear material and, in particular, to a reel including an improved reciprocating mechanism for distributing linear material across a rotating reel drum. 
     2. Description of the Related Art 
     Reels for spooling linear material, such as a hose or wire, onto a rotating drum have incorporated reciprocating motion of a guide through which the linear material passes, to advantageously cause the linear material to be wrapped substantially uniformly around most of the surface area of the drum. 
     Several methods have been utilized in the past for achieving such reciprocating motion. One common approach is to use a rotating reversing screw which causes a guide to translate back and forth in front of a rotating drum. For example, such an approach is shown in U.S. Pat. No. 2,494,003 to Russ. However, such reversing screws tend to wear out quickly, degrading reel performance and necessitating frequent replacement. Further, such reversing screws are bulky and increase the size of the reel assembly. 
     Another approach for producing reciprocating motion of the guide is to use a motor to control a rotating screw upon which the guide translates. In this class of reels, the motor reverses the direction of rotation of the screw whenever the guide reaches an end of the screw. Unfortunately, the repeated reversing of the motor increases the spooling time and causes the motor to wear down sooner. Other reels have incorporated significantly more complicated gear mechanisms for achieving the reciprocating motion. 
     Many reel constructions include exposed moving parts, such as the reel drum, guide, and motor. Over time, such moving parts can become damaged due to exposure. For example, an outdoor reel is exposed to sunlight and rain. Such exposure can cause the moving parts of the reel to wear more rapidly, resulting in reduced performance quality. 
     Thus, there is a need for a compact reel assembly having a reel with an improved reciprocating mechanism for efficiently distributing linear material across the reel drum. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is a principle object and advantage of the present invention to overcome some or all of these limitations and to provide an improved reel incorporating a reciprocating mechanism. 
     In accordance with one embodiment, a reciprocating mechanism is provided, comprising an element adapted to rotate about a first axis and a worm gear extending along the first axis and coupled with respect to the element. The reciprocating mechanism also comprises a driven gear meshingly engaged with the worm gear, the driven gear configured to rotate about a driven gear axis. A lever is coupled to and configured to rotate along with the driven gear about the driven gear axis, the lever having an elongated slot. A guide member defines an encircling slot in a plane generally parallel to a plane within which the lever rotates. An elongate member has a portion extending completely or partially through, and adapted to move along, the elongated slot of the lever, the elongate member portion also extending completely or partially through, and adapted to move along, the encircling slot of the guide member. The elongate member is pivotably secured to a frame or housing such that the elongate member is configured to pivot about an axis generally perpendicular to the plane of the encircling slot. Rotation of the element about the first axis produces rotation of the worm gear about the first axis, the rotation of the worm gear producing rotation of the driven gear and the lever about the driven gear axis, the rotation of the lever guiding the portion of the elongate member along the encircling slot in order to reciprocatingly pivot the element relative to the frame or housing about a second axis generally transverse to the first axis. 
     In accordance with another embodiment, a reel assembly is provided. The reel assembly comprises a drum configured to rotate about a drum axis and to receive a linear material being wrapped around a spool surface of the drum as the drum rotates about the drum axis and a housing substantially enclosing the drum, a portion of the housing defining an aperture configured to receive the linear material therethrough. The reel assembly also comprises a reciprocating mechanism, comprising a lever operatively coupled with respect to the drum and defining an elongated slot. A guide member is disposed proximal the lever, the guide member defining an encircling slot. An elongate member has a portion extending completely or partially through the elongated slot of the lever and extending completely or partially through the encircling slot of the guide member, the elongate member being pivotably coupled with respect to the housing. The rotation of the drum about the drum axis rotates the lever, which in turn guides the elongate member portion along the encircling slot so as to reciprocatingly rotate the drum relative to the housing about a reciprocation axis generally transverse with respect to the drum axis. 
     In accordance with another embodiment, a reel assembly is provided, comprising a drum configured to rotate about a drum axis and to receive a linear material being wrapped around a spool surface of the drum as the drum rotates about the drum axis and a housing substantially enclosing the drum, a portion of the housing defining an aperture configured to receive the linear material therethrough. The reel assembly also comprises a reciprocating mechanism configured to produce relative reciprocating rotation between the drum and the housing about an axis generally orthogonal to the drum axis and at a generally constant angular velocity between endpoints of the reciprocation for a given drum rotating speed about the drum axis. 
     In accordance with still another embodiment, a method for spooling linear material is provided. The method comprises rotating a drum about a first axis at a first speed, reciprocatingly rotating the drum about a second axis generally perpendicular to the first axis at a generally constant second speed between endpoints of the reciprocation, and drawing linear material onto the drum, the linear material being spooled across a surface of the drum by the reciprocating rotation of the drum. 
     For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. 
     All of these aspects are intended to be within the scope of the invention herein disclosed. These and other aspects of the present invention will become readily apparent to those skilled in the art from the appended claims and from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects and advantages of the present invention will now be described in connection with a preferred embodiment of the invention, in reference to the accompanying drawings. The illustrated embodiment, however, is merely an example and is not intended to limit the invention. The drawings include the following figures. 
         FIG. 1  is a front perspective view of a disassembled reel, including a housing, in accordance with one embodiment. 
         FIG. 2  is a bottom perspective view of a drum assembly with reciprocating mechanism, in accordance with one embodiment disclosed herein. 
         FIG. 2A  is a schematic illustration of a gear reduction between a motor and a gear of the reciprocating mechanism shown in  FIG. 2 . 
         FIG. 3  is a top and side perspective view of one embodiment of a drum assembly. 
         FIG. 4  is bottom and side perspective view of the drum assembly in  FIG. 3 . 
         FIG. 5  is a top partially cut-away perspective view of the reciprocating mechanism shown in  FIG. 2 . 
         FIG. 6  is a bottom partially cut-away view of the reciprocating mechanism for a reel shown in  FIG. 2 . 
         FIG. 7  is a bottom and side partially cut-away perspective view of reciprocating mechanism of  FIG. 2 . 
         FIG. 8A  is a top view of the drum assembly of  FIG. 2  illustrating one position in the reciprocating rotation of the drum. 
         FIG. 8B  is a top view of the drum assembly of  FIG. 2  illustrating another position in the reciprocating rotation of the drum. 
         FIG. 8C  is a top view of the drum assembly of  FIG. 2  illustrating another position in the reciprocating rotation of the drum. 
         FIG. 8D  is a top view of the drum assembly of  FIG. 2  illustrating another position in the reciprocating rotation of the drum. 
         FIG. 8E  is a top view of the drum assembly of  FIG. 2  illustrating another position in the reciprocating rotation of the drum. 
         FIG. 9A  is a top and front perspective view of the reel assembly of  FIG. 1  illustrating one position in the reciprocating rotation of the drum. 
         FIG. 9B  is a top and front perspective view of the reel assembly of  FIG. 1  illustrating another position in the reciprocating rotation of the drum. 
         FIG. 10  is a top partially cut-away perspective view of another embodiment of a reciprocating mechanism. 
     
    
    
     For ease of illustration, some of the drawings do not show certain elements of the described apparatus. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following detailed description, terms of orientation such as “top,” “bottom,” “upper,” “lower,” “front,” “rear,” and “end” are used herein to simplify the description of the context of the illustrated embodiments. Likewise, terms of sequence, such as “first” and “second,” are used to simplify the description of the illustrated embodiments. Because other orientations and sequences are possible, however, the present invention should not be limited to the illustrated orientation. Those skilled in the art will appreciate that other orientations of the various components described above are possible. 
       FIG. 1  illustrates one embodiment of a reel assembly  100  substantially enclosing a drum assembly  10  in a housing. In the illustrated embodiment, the housing includes an upper or top shell portion  22  and a lower or bottom shell portion  24 . Additionally, the upper and lower shell portions  22 ,  24  have the shape of upper and lower domes  26 ,  28 , respectively, so that the reel assembly  100  has a generally spherical shape. However, the upper and lower shell portions  22 ,  24  can have any suitable shape, such as cylindrical and aspherical. As shown in  FIG. 1 , the upper shell portion  22  includes a guide member  30  with an aperture (not shown), which preferably guides a linear material, such as a water hose, into and out of the housing of the reel assembly  100  as the linear material is wound onto or unwound from the drum assembly  10 . Additionally, the lower shell portion  24  is preferably supported by a plurality of legs  32 . However, other types of legs or support structures can be used. In one embodiment, a circumferential stand supports the lower shell portion  24  on a support surface. Preferably, the lower shell portion  24  is movably supported with respect to a lower support surface, so that the reel assembly  100  is capable of moving along the surface. For example, the legs  32  or support structure can have rollers. 
     As seen in  FIGS. 1 and 2 , the drum assembly  10  defines a first or drum axis X about which the drum rotates. Additionally, a housing or second axis Y extends through the reel assembly  100 . In a preferred embodiment, the housing axis Y is generally vertical and the drum axis X is generally horizontal, so that the housing axis Y is generally orthogonal to the drum axis X. Further details on reel assemblies can be found in U.S. Pat. No. 6,279,848, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification. 
       FIGS. 2-7  illustrate one embodiment of a reciprocating mechanism  200  for a reel assembly. In one embodiment, the reciprocating mechanism  200  can be used with the reel assembly  100  illustrated in  FIG. 1 . The reciprocating mechanism  200  preferably includes a frame  210  comprising a top frame and a bottom frame. In the illustrated embodiment, the top frame includes an upper ring  212  and the bottom frame includes a lower ring  214  (see  FIG. 1 ). In a preferred embodiment, the upper ring  212  is coextensive with and removably disposed on the lower ring  214 . In another embodiment, the upper ring  212  overlaps the lower ring  214 . The upper and lower rings  212 ,  214  are preferably fastened to the upper and lower shell portions  22 ,  24 , respectively, via any suitable method. In one embodiment, the shell portions  22 ,  24  can be fastened to the rings  212 ,  214 , respectively, using bolts or screws. In another embodiment, the shell portions  22 ,  24  can be clamped, welded, or adhesively secured to the rings  212 ,  214 . 
     In a preferred embodiment, the upper ring  212  can rotate relative to the lower ring  214 . For example, bearings  213 , as shown in  FIG. 1 , can be disposed between the upper and lower rings  212 ,  214 . Preferably, the rings  212 ,  214  are sized to enclose a drum assembly  220 , which consists of first and second endplates  222 ,  224  and a drum  226  disposed between the endplates  222 ,  224 . As shown in  FIGS. 2 and 5 , a ring gear  230  is preferably attached to the first endplate  222 . 
     The ring gear  230  is coupled to a shaft  232 , which preferably extends into a hollow portion  228  of the drum  226  and rotatingly couples to a shaft support  234  disposed inside the hollow portion  228  (see  FIG. 3 ). In one preferred embodiment, the shaft support  234  is disposed generally at the center of the upper ring  212 . In another embodiment, the shaft support  234  can be offset from the center of the upper ring  212 . Preferably, the shaft support  234  allows the shaft  232  to rotate freely therein. For example, in one embodiment, the shaft  232  can couple to the shaft support  234  via a bearing (not shown) disposed therein. As explained more fully below, the shaft  232  is preferably hollow so as to convey water. Additionally, the connection between the shaft  232  and the shaft support  234  preferably inhibits the leakage of fluid therebetween, as further discussed below. For example, in one embodiment, the connection between the shaft  232  and the shaft  234  includes a substantially water-tight seal. 
     The shaft  232  also connects to a fitting  236 . The fitting  236  couples to a conduit member  262  disposed within the lower shell portion  24  and disposed below the lower ring  214 . In the illustrated embodiment, the conduit member  262  is curved and has a first end  264  that connects to the fitting  236 , which in turn connects to the shaft  232 . The conduit member  262  has a second end  266  disposed generally along an axis Y 2  extending generally perpendicular to the upper and lower rings  212 ,  214 . In one embodiment, the shell axis Y and the axis Y 2  are coaxial. Preferably, the second end  266  extends through an aperture (not shown) in the lower shell portion  24 . In one preferred embodiment, the fitting  236  is not coupled to the upper ring  212 . Further description of the fitting  236  and the conduit member  262  is provided below. 
     As shown in  FIG. 5 , an upper ring support member  238  extends from a surface  240  of the upper ring  212 . In the illustrated embodiment, the upper ring support member  238  defines a slot  239  therein. Preferably, the slot  239  extends along the length of the support member  238  and is sized to slidingly receive one end  245   a  of a support frame  245  coupled to the conduit member  262 . As shown in  FIG. 5 , the support frame  245  has a horizontal portion and a vertical portion, and the end  245   a  extends from the horizontal portion of the support frame  245 . In one embodiment, at least one bearing (not shown) is disposed in the slot  239  to facilitate the sliding of the end  245   a  of the support frame  245  relative to the slot  239 . However, other suitable methods for facilitating the sliding of the support frame  245  in the slot  239 , such as, for example, applying a lubricant to at least one of the slot  239  and the end  245   a  of the support frame  245 . 
     Preferably, the shaft  232  includes a worm gear section  242 , which extends along at least a portion of the shaft  232 . In one embodiment, the worm gear section  242  extends along substantially the entire length of the shaft  232 . The shaft  232  is preferably integrally formed with the worm gear section  242 . In another embodiment, the shaft  232  is removably coupled to the worm gear section  242  via, for example, a spline connection. 
     As shown in  FIGS. 2 ,  6  and  7 , the worm gear section  242  preferably meshingly engages a top or driven gear  244  mounted on and below the support frame  245 . As used herein, the “engagement” of two gears means that the teeth of one gear are engaged with the teeth of the other gear. The top gear  244  is in turn coupled to a lever  246  (see  FIG. 5 ), for example, via a pin  246   a  (see  FIG. 8B ) that extends along an axis of rotation of the top gear  244 . As shown in  FIG. 5 , the lever  246  defines an elongated slot  247  therein. In a preferred embodiment, the top gear  244  and lever  246  are lockingly coupled, so that rotation of the top gear  244  results in rotation of the lever  246 . In another embodiment, the top gear  244  and lever  246  are integrally formed. The lever  246  is preferably coupled to an elongate member  248 , so that a first end or portion  248   a  of the elongate member  248  extends through and is adapted to slidingly move along the slot  247 , while a second end or portion  248   b  of the elongate member  248  is pivotably secured to the support member  238 . In one embodiment, the first end  248   a  of the elongate member  248  extends completely through the slot  247  of the lever  246  and at least partially or completely through the slot  252  of the guide member  250  (described below). In another embodiment, the lever  246  is below the guide member  250 , and the first end  248   a  of the elongate member  248  extends completely through the slot  252  and at least partially or completely through the slot  247  of the lever  246 . 
     As best shown in  FIG. 5 , a guide member or track  250  is disposed adjacent the lever  246 , so that the guide member  250  extends along a plane generally parallel to a plane within which the lever  246  rotates. In the illustrated embodiment, the guide member  250  defines an encircling slot  252 . In the illustrated embodiment, the encircling slot  252  extends only partially through the guide member  250 , so as to define a groove or recess. In another embodiment, the encircling slot  252  can extend completely through the guide member  250 . In the illustrated embodiment, the first end  248   a  of the elongate member  248  extends partially through and is adapted to move along the encircling slot  252  of the guide member  250 , so that the elongate member  248  pivots about an axis generally perpendicular to the plane of the encircling slot  252 . In another embodiment, the first end  248   a  of the elongate member  248  can extend completely through the encircling slot  252  of the guide member  150 . In the illustrated embodiment, the guide member  250  is disposed between the support frame  245  and the lever  246  and is preferably secured to the support frame  245 . However, in another embodiment, the lever  246  can be positioned between the support frame  245  and the guide member  250 . As used herein, encircling means surrounding, but is not necessarily limited to a circular surrounding. In the illustrated embodiment, the guide member  250  is shaped somewhat in the form of a “D” (see  FIG. 8A ). However, the guide member  250  can have other suitable shapes, such as circular, oval, triangular and trapezoidal. 
     As shown, for example in  FIG. 2 , the reciprocating mechanism  200  includes a motor  254  mounted to the support frame  245 . In the illustrated embodiment, the motor  254  is disposed below the lower ring  214  and is housed in the lower shell portion  24 . Preferably, the motor  254  is an electric motor. The motor  254  preferably operatively connects to the ring gear  230  via a drive gear  256 . For example, the motor  254  can, through a gear reduction comprising multiple gears, drive the drive gear  256 , which can operatively drive the ring gear  230  at a desired speed. One example of a gear reduction is shown in  FIG. 2A , which includes a motor gear  254   a  that meshingly engages and drives the drive gear  256 . In the illustrated embodiment, another gear  257  (also shown in  FIG. 6 ), which is preferably co-axial with the drive gear  256 , meshingly engages and drives the ring gear  230 . However, the gear reduction can include any number of gears and have other configurations for operatively coupling the motor  254  to the ring gear  230 . Additionally, any desired gear ratio can be used. In one embodiment, the gear reduction has a gear ratio of 2 to 1. In another embodiment, the gear reduction has a gear ratio of 4 to 1. In still another embodiment, the gear reduction has a gear ratio of between about 2 to 1 and about 25 to 1. One example of a gear reduction between the motor  254  and the ring gear  230  is schematically shown in  FIG. 2A . 
     The reel  100  can also employ an electronic motor controller and associated electronic componentry for controlling the speed and direction of the motor  254 . For example, while spooling the linear material  268  (see  FIG. 9A ) onto the drum  226 , a motor-controller can be employed to vary the motor speed based upon the length of unwound linear material  268 . It will be appreciated that if the motor speed is constant, the inwardly pulled linear material  268  tends to move increasingly faster due to the increasing diameter of the spool itself. A motor-controller can adjust the motor speed to more safely control the motion of the linear material  268  during spooling. Also, a motor-controller can be used to slow or stop the motor  254  just before the linear material  268  becomes completely spooled onto the drum  226 . Otherwise, the linear material  268  would get pulled into the housing or, if there is an object at the end of the linear material  268  (e.g., a nozzle), the object may whip against or otherwise impact the housing or a person near the housing. In addition, a motor-controller can even be used to assist the user during unspooling of the linear material  268  (i.e., powered unspooling). One example of a motor-controller for a reel is disclosed in U.S. Pat. No. 7,350,736 to Caamaño et al., entitled Systems and Methods for Controlling Spooling of Linear Material, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification. Also, the motor  254  and/or motor-controller can be operated via a remote control. An exemplary remote control system for a motorized reel is disclosed in U.S. Pat. No. 7,503,338 to Harrington et al., the entire contents of which are hereby incorporated by reference and should be considered a part of this specification. In a preferred embodiment, a remote control is engaged on the spooled linear material  268  at or near its outward end. The remote control can send signals wirelessly (e.g., via radio frequency signals) or through a wire within the linear material. 
     As shown in  FIGS. 3-4 , the reciprocating mechanism  200  also has a platform  258  that extends between the shaft support  234  and the edge of the upper ring  212 . As shown in  FIG. 8A , the platform  258  is disposed generally opposite the upper ring support member  238 . The platform  258  preferably extends into the hollow portion  228  of the drum  226 . In one embodiment, the platform  258  can support a battery  259 , as shown in  FIG. 3 , thereon so that the battery  259  is disposed between the second endplate  224  and the upper ring  212 . Preferably, the battery  259  provides power to the motor  254 . Details of one suitable battery for use with the reciprocating mechanism  200  can be found in U.S. Pat. No. 7,320,843 to Harrington, entitled Battery Assembly With Shielded Terminals, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification. 
     As shown in  FIGS. 3 and 4 , the platform  258  preferably supports the shaft support  234  thereon. In the illustrated embodiment, a pin  234   a  of the shaft support  234  pivotably extends through an opening  258   a  of the platform  258 , permitting the shaft support  234  to rotate with respect to the platform  258  about a vertical axis extending through the opening  258   a . This pivot connection advantageously allows the reciprocating mechanism  200  to reciprocatingly rotate the drum  226  about the shell axis Y, as further discussed below. 
     As discussed above, the fitting  236  couples to the conduit member  262 . In one embodiment, the second end  266  of the conduit  262  is configured to removably attach to a water hose (not shown). For example, the second end  266  can have a threaded surface for threaded engagement with a corresponding thread on the hose (e.g., a standard hose fitting). In another embodiment, the second end  266  can have a quick-disconnect portion configured to removably engage a corresponding quick-disconnect portion on the hose. Other mechanisms for connecting the hose and the conduit  262  are also possible. Preferably, water provided through the hose flows through the conduit  262  and through the fitting  236  and shaft  232  into the shaft support  234 . In one preferred embodiment, the shaft support  234  communicates, for example, via a second conduit (not shown), with a second fitting  268  (see  FIGS. 2 and 8A ) disposed on the surface of the drum  226 . In this manner, water can be supplied to a hose that has been spooled on the drum  226  and has been removably fastened to the second fitting  268 . Any suitable mechanism for removably fastening the hose and the second fitting  268  can be used, such as a threaded engagement or a quick-disconnect connection. Further details on such an arrangement is shown, for example, in U.S. Pat. No. 6,981,670 to Harrington, entitled Reel Having Apparatus for Improved Connection of Linear Material, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification. 
     The rings  212 ,  214  and gears  230 ,  242 ,  244 ,  256  of the reciprocating mechanism  200  are preferably made of a strong material resistant to breaking. In one embodiment, the rings  212 ,  214  and gears,  230 ,  242 ,  244 ,  256  can be made of a metal or metal alloy, such as stainless steel and aluminum. However, other materials can also be used. In another embodiment, the rings  212 ,  214  and gears  230 ,  242 ,  244 ,  256  of the reciprocating mechanism  200  can be made of a hard plastic. In still another embodiment, the gears  230 ,  242 ,  244 ,  256  may be formed of acetyl, such as Delrin® sold by Dupont, headquartered in Wilmington, Del. Various combinations of these materials are also possible. 
     The use of the reciprocating mechanism  200  to reciprocatingly rotate the drum assembly  220  is illustrated in  FIGS. 8A-8E . Actuation of the motor  254  preferably rotates the ring gear  230  in one direction via the drive gear  256  and, optionally, a gear reduction assembly (see e.g.,  FIG. 2A ) operatingly coupling the motor  254  to the drive gear  256 . Rotation of the ring gear  230  in turn rotates the reel drum  226  via the first endplate  222 . Rotation of the ring gear  230  also rotates the shaft  232  in the same direction, causing the worm gear section  242  to also rotate. Rotation of the worm gear section  242  rotates the top or driven gear  244 , which in turn rotates the lever  246  about the axis of the top gear  244 . As the lever  246  rotates, it guides the first end  248   a  of the elongate member  248  about the axis of the top gear  244  and along the encircling slot  252  of the guide member  250 , thus moving the elongate member back and forth. As the lever  246  rotates and guides the first end  248   a  of the elongate member  248  about the axis of the top gear  244 , the first end  248   a  also slides along the slot  247  of the lever  246 . The movement of the elongate member  248  in turn reciprocatingly rotates the drum  226  relative to the upper ring  212  about the shell axis Y via the pivot connection  234   a ,  258   a  between the shaft support  234  and the platform  258 . In one embodiment (e.g., if the slot  252  is circular), the reciprocating mechanism  200  reciprocatingly rotates the drum  226  so that an angular velocity of the drum about the shell axis Y fluctuates generally sinusoidally. 
     In a preferred embodiment, the slot  247  on the lever  246  and the encircling slot  252  on the guide member  250  allow the drum  226  to reciprocate about the shell axis Y at a generally constant angular velocity between endpoints of the reciprocation for a given drum  226  rotation speed about the drum axis X. It is the general D-shape of the slot  252  that produces this outcome. It will be appreciated that other sizes and shapes of the slot  252 , slot  247 , lever  246 , and elongate member  248  can achieve the goal of a generally constant angular velocity between endpoints of the reciprocation. 
     In one embodiment, the upper shell portion  22 , which is preferably fixed with respect to the upper ring  212 , and the aperture guide  30  in the upper shell portion  22 , remain in a fixed position while the drum  226  reciprocatingly rotates inside the housing to spool and unspool the linear material  268 , as shown in  FIGS. 9A-9B . In another embodiment, the reciprocating mechanism  200  reciprocatingly rotates the upper shell portion  22  about the shell axis Y, while the drum  226  is preferably in a substantially fixed angular position. 
     The substantially constant angular velocity of the drum  226  about the shell axis Y that is generated by the reciprocating mechanism  200  advantageously allows the spooling and unspooling of linear material onto the drum  226  with increased efficiency. Such increased efficiency allows the use of a drum  226  having a smaller width to spool the same amount of linear material, requires less power to spool the same amount of linear material, and allows for an overall reduction in the size of the reel assembly  100 . The reciprocating mechanism  200  according the embodiments discussed above also advantageously require about 30% less parts to operate than conventional reciprocating mechanisms. 
       FIG. 10  illustrates another embodiment of a reciprocating mechanism  200 ′. The reciprocating mechanism  200 ′ is similar to the reciprocating mechanism  200 , except as noted below. Thus, the reference numerals used to designate the various components of the reciprocating mechanism  200 ′ are identical to those used for identifying the corresponding components of the reciprocating mechanism  200  in  FIG. 5 , except that a “′” has been added to the reference numerals. 
     The reciprocating mechanism  200 ′ includes a top or driven gear coupled to a lever  246 ′ via a pin  246   a ′ that extends along the axis of the top gear. The top gear and the lever  246 ′ are preferably lockingly coupled, so that rotation of the top gear about the top gear axis results in rotation of the lever  246 ′ in the same direction. In another embodiment, the top gear and the lever  246 ′ can be integrally formed. The lever  246 ′ is preferably pivotably coupled to an elongate member  248 ′ at a first pivot point  248   a ′. The elongate member  248 ′ is also pivotably secured to a support member  238 ′ at a second pivot point  248   b ′. The relative motion between the lever  246 ′ and the elongate member  248 ′ advantageously generates a reciprocating motion of the drum  226 ′ about a drum axis. 
     In a preferred embodiment, the gear ratio of the gear reduction and size of the ring gear  230 , worm gear  242 , drive gear  256 , and top gear  244 , as well as the lengths of the levers  246  and elongate member  248 , are selected to reciprocatingly rotate the drum  226  relative to the upper ring  212  about the shell axis Y so as to cause a linear material to be generally uniformly wound onto the reel drum. Thus, the reciprocating mechanism  200  advantageously allows a linear material to be uniformly wound onto the drum  226 . 
     As discussed above, the upper ring  212  and drum assembly  220  preferably rotate freely relative to the lower ring  214 , preferably through 360 degrees and more, as desired. Therefore, the upper shell portion  22  coupled to the upper ring  212  can advantageously rotate freely relative to the lower shell portion  24 , which is preferably fixed with respect to the lower ring  214 . 
     Of course, the foregoing description is that of certain features, aspects and advantages of the present invention, to which various changes and modifications can be made without departing from the spirit and scope of the present invention. Moreover, the reciprocating mechanism for a reel assembly need not feature all of the objects, advantages, features and aspects discussed above. Thus, for example, those skill in the art will recognize that the invention can be embodied or carried out in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. In addition, while a number of variations of the invention have been shown and described in detail, other modifications and methods of use, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is contemplated that various combinations or subcombinations of these specific features and aspects of embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the discussed reciprocating mechanism for a reel assembly.

Technology Category: 4