Two-Piece Reel Assembly

This application claims the benefit of U.S. Provisional Application Ser. No. 63/654,973, filed Jun. 1, 2024, the disclosure of which is incorporated herein by reference in its entirety.

The present disclosure relates generally to the field of reels or spools that support wound media.

Traditional reel cores consist of a hollow tube around which cable, wire or other flexible media is wound, and flanges that axially retain the media on the core. Various methods can be used for assembling the hollow tube cores to the flanges, including stapling, bolting, gluing, welding, or a combination of one or more methods. Reels can be made of plastic and/or paper products to reduce costs, and can have appreciable strength and robustness.

Moreover, it has become desirable to provide a reel in which all of the components are plastic for, among other things, ease of recycling. Thus, providing a customer with reel components that need to be assembled using staples or bolts defeats this purpose. Furthermore, it can be cost and/or space prohibitive to obtain the equipment necessary for other types of assembly, such as stapling, screwing, bolting, welding and gluing. With if any of the above-mentioned assembly methods, significant secondary assembly activity is still required to produce the reel.

Accordingly, there is a need for a reel design that reduces some of the costs associated with assembly of the reels, as well as component costs.

At least some embodiments described herein address the above needs, as well as others, by providing a snap-together two-part reel wherein each flange is formed with an attached portion of the core. Two parts, each having a flange and a portion of a core, are assembled together. In various embodiments, snap together parts are used to avoid the need for additional fasteners, resulting in cost and manufacturing savings. In some embodiments, the two parts or elements have an identical structure, thereby further simplifying the manufacturing process.

A first embodiment is a reel for supporting wound flexible media that includes first and second elements. The first element has a first flange and a first set of legs extending in a directly axially away from a first side of the first flange. The second element has a second flange and a second set of legs extending axially from a first side of the second flange. The first set of legs and the second set of legs are interleaved in a circumferential direction to form at least a portion of a core of the reel disposed between the first flange and the second flange, and around which flexible media may be wound and supported. The first set of legs is configured to snap connect with the second element. In some embodiments, the second set of legs is also configured to snap connect with the first element.

In another embodiment, a reel for supporting wound flexible media includes first and second elements. The first element has a first flange and at least one axial extension extending axially from a first side thereof. Similarly, the second element has a second flange and at least one axial extension extending axially from a first side thereof. The second element has a substantially identical structure as the first element, such that they are interchangeable. The first element is configured to snap fit with the second element such that the at least one axial extension of the first element and the at least one axial extension of the second element form a core of the reel, disposed between the first flange and the second flange, and around which flexible media may be wound and supported.

The above-described features and advantages, will be readily understood by those of ordinary skill in the art by reference to the following detailed description and the accompanying drawings.

shows a top perspective view of an apparatusfor supporting wound flexible media that includes a first flange, a second flange, and a core.shows a bottom perspective view of the apparatusof. The apparatus in this embodiment is referred to as a reel.shows a top perspective view of a kitthat may be assembled into the reel. andshows a side plan view of the reelin a partially assembled state. The reelis configured to support wound flexible media such as electrical cable, optical fiber, and the like. The coreis tube structure, which in this embodiment is round and cylindrical, around which the flexible media, not shown, may be wound. Each of the flanges,is in the form of a disk or annulus.

More particular, with reference to, the flangehas an inner or first side, and an outer or second side. The flangehas a main plate, and has a plurality of annular and radial ribs and other molded structuresextending axially outward from the main plateon the second side. The structuresare configured to provide strengthening and other advantages that would be known to those of ordinary skill in the art. In this embodiment, the flangeis substantially identical, having a corresponding inner or first side, an outer or second side(not visible in), a main plateand molded ribs and other structures, also not visible in). Both flanges,have holes for winding, handling and/or other purposes. While the flanges,in the exemplary embodiment of the reelare circular, flanges in other embodiments may take different shapes. By “substantially identical”, it is meant that the flangesandare interchangeable, such that the reelmay be made of two flanges, or two flanges. In some cases, the flangesandare made by the same mold

shows the unassembled reel, which forms a kitwhich may be subsequently assembled. With specific reference to, the reelis formed of a first elementand a second element. The first elementincludes the flangerigidly affixed to a partial core. The first elementis preferably formed from a single piece of injection molded plastic. Similarly, the second elementincludes the flangerigidly affixed to a second partial core, and is preferably formed from a single piece of injection molded plastic.

With reference to, the partial coreis formed from one or more axial extensions that extend from the first sideof the flange. In this embodiment, the axial extensions comprise three legs,,, each comprising an arcuate plate having a respective outer arcuate surface,,and a respective, corresponding inner arcuate surface,,. The three legs,, andare spaced apart and dispose such that their arcuate surfaces,, andform a partial cylinder, which is the partial core. The partial corealso includes three receivers,and. In this embodiment, the legs,,extend directly from the flange.

In this embodiment, the legs,,are substantially identical to each other, and receivers,andare substantially identical, for reasons that will be discussed below. At a minimum, the outer arcuate faces,,, are substantially identical to each other, and the receivers,, andare substantially identical.

The second partial coresimilarly includes three legs,,, each having an outer arcuate surface,,, an inner arcuate surface,,, and leg receivers,,. The receivers,, andare disposed between adjacent pairs of legs,,. As a result, the second partial coreincludes an alternating pattern of legs,,and receivers,,. The second partial corein this embodiment has a structure that is identical to the first partial core.

In this embodiment, each of the legs,,extends axially from a proximal end, that is at, or proximate to, the first sideof the flange, to a distal end that is further away from the first sideof the flange. In this embodiment, each leg of the first set of legs,, andextends axially substantially entirely from first flangeto the second flange. In addition, the outer arcuate surfaces,,in this embodiment have arcuate lengths at the proximal end that are greater than arcuate lengths of the distal end. In other words, the outer arcuate surfaces,,all get arcuately narrower as they extend away from the flange

Similarly in this embodiment, each of the legs,,extends axially from a proximal end that is at or proximate to the first sideof the flange, to a distal end that is further away from the first sideof the flange. In this embodiment, each leg of the second set of legs,, andextends axially from second flangeto the first flange. In addition, the outer arcuate surfaces,,in this embodiment have arcuate lengths at the proximal end that are greater than arcuate lengths of the distal end. In other words, the outer arcuate surfaces,,all get arcuately narrower as they extend away from the flange

In general, the reelis formed by combining, connecting and/or assembling the first elementto the second element, such that the legs,andare interleaved with the legs,, andin the circumferential direction to form the core. To this end, each of the legs,,of the first elementis axially aligned with a corresponding receiver,andof the second element, as shown in. The legs and receivers of the two elements,are designed such that in such axial alignment, each of the legs,,of the second elementis axially aligned with a corresponding receiver,andof the first element, as shown in. In this embodiment, because the legs and receivers on each element,are the same, no particular receiver need be aligned with any particular leg.

As illustrated in, after alignment, the first elementis axially advanced toward the second element. In particular, each of the legs,,of the first elementis axially advanced toward and into a corresponding receiver,andof the second element, and each of the receivers,andof the first elementis advanced toward and onto a corresponding leg,,of the second element, as shown in. Connecting features of the legs and receivers then engage to secure (e.g. snap connect) the first elementto the second elementto form the completed reel, as shown in. Once assembled, the outer arcuate faces,,,,, andcooperated to form a cylindrical or other rounded tube, which is the coreof the reel.

shows a fragmentary cutaway view of the reelshowing the interconnection of one of the legswith the receiver. With reference to, the legincludes its arcuate plate, a connection shaftand a connector. The arcuate platedefines the outer arcuate surfaceand the arcuate inner surface. The arcuate plateand the surfaces,, extend arcuately from a first edgeto a second edge. As discussed above, the arcuate plateextends substantially the axial length of the corein this embodiment, from a proximal endthat is adjacent and attached to the flange, to the distal end.

The connection shaftis disposed on the arcuate inner surfaceand extends at least along a part of the inner surfacetowards and to the distal end. The connectorextends from the connection shaftbeyond the distal endof the plate. The connection shaftin this embodiment has opposing long edges,that slightly converge towards each other as the connection shaftcontinues toward the distal end. As shown most clearly in, the connectorincludes an armand a headat the end of the arm. The headextends radially inward from the arm, and includes retention surface or latchand a chamfered forward edge.

With reference to, the structure of the receiveris provided with additional reference to the structure of the receiverwhich has an identical structure. The same reference numbers will be used to describe the same structures on the receivers,,,,, and. Referring again generally to, each of the receivers,includes first and second guiding walls,, reinforcement ribs,, a T-base. The guiding walls,extend arcuately inward from opposing edges of adjacent legs. For example, the guiding walls,ofextend arcuately inwardly from the edges of the legs,. The guiding walls,define between themselves a voidthat is configured to receive and fit with the connection shaftwhen the reelis assembled.

The T-base, as shown inis secured to the flangeand includes an axially inner arm, an axially outer arm, and a cantileverextending radially outward from the arms,. The reinforcement ribextends in an at least partially inclined manner from the guiding wallto the cantileverand an axially inner arm. The axially outward side of the cantileverincludes a spacefor receiving the headof the connector.

As shown in, when the reelis assembled, the latchis disposed in the space, and engages the axially outward surface of the cantilever. The chamfered edgeassists in allowing the headto advance passed the cantileverduring assembly. During axial insertion, some elastic deformation of the connectortakes place, for example, in the armas the chamfered edgeadvances against the axially inward corner of the cantilever. Once cleared, the connectorrecovers its original shape and the latchextends into the space, where it assists in retaining the connection of the elements,to each other.

All of the other receivers,,,, andhave the same structure. Similarly, the legs,,,,,have the same structure. This allows the connection of the reel elements,to be accomplished without specifically aligning the legs and receivers in a single possible axial alignment.

It will be appreciated that the orientation of the latches (e.g. latch) on the connectors (e.g. connector) of elements,, extending radially inward, can provide enhanced connection strength when the reelis in use. In particular, when the reelis wound with flexible media, such as optical fiber, wire or cable for example, the wound media imparts a radially inward compression force on the core. This further drives the latchunder the cantilever, thereby strengthening the attachment of the elements,to each other.

show an alternative embodiment of a reel(in unassembled formin) that has the same identical structure as the reel, and uses the same reference numbers, except as noted below. In particular, the reelincludes an additional feature, a notch, which is formed by discontinuities of the arcuate plate edges of adjacent legs,. Specifically the notchis created by cooperating discontinuities,disposed at the proximal end of one legand the distal end of the adjacent leg. The notchis a feature that can be used on automated winding machines as is known in the art, for example, certain winding machines sold by Windak.

In the exemplary embodiments described above, the manufacturing process may be simplified. The elements,reels can be snapped together to form a full reel(or), without any extra parts or secondary off-line assembly. In some cases, the assembly can be completed at the injection molding station by the same operator who packages the reel for inventory storage and shipping.

It will be appreciated that the above-described embodiments are merely illustrative, and that those of ordinary skill in the art may readily devise their own implementations and modifications that incorporate the principals of the present invention and fall within the spirit and scope thereof. For example, it will be appreciated that more or fewer than three legs and receivers may be used in on each reel element,. It will be appreciated that the reel pieces,need not be identical in structure, and still obtain some of the benefits of the embodiments described herein. It will also be appreciated that the flanges,may have different designs, and can have different shapes.