A composition for making a molded article such as a reel flange, and a method making the same, are provided. The composition may consist essentially of about 75-95 wt % dry waste wood and about 10-25 wt % binder such as melamine-urea-formaldehyde (MUF) or PMUF resin. The waste wood may be recycled wood fiber from pine or other hardwoods, sawdust and wood chips. The method comprises mixing dry waste wood with MUF or PMUF resin binder to make a wood/resin mixture, and compressing the wood/resin mixture in a mold cavity at a pressure and temperature.

A reel for carrying cable, wire or other wound materials is provided. The reel comprises a paperboard drum and molded flanges. The drum forms a friction fit with a hub located on each flange and forms an adhesive bond at an annular groove defined by each flange. The friction fit and the adhesive bond secure the flange to the drum sufficiently to eliminate the need for bolts or other attachment means.

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

A spool for winding strand-shaped material having flange discs (22, 24) with an outer flange surface and an inner flange surface (21, 23) as well as a method for manufacturing the spool. The discs have a central through bore (30) that is surrounded by an annular recess (25) with an annular wall (26) positioned in the inner flange surface. A tubular spool core (10) has front surfaces which are connected in a materially bonded manner to the annular wall (26) inside the annular recess (25) of the flange discs (22, 24), wherein at least one channel (32) is provided next to the annular wall (26) inside the annular recess (25) for receiving liquefied connection material. The spool core (10) has approximately the same diameter as the annular wall (26) inside the annular recess (25).

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

A spool for winding strand-shaped material having flange discs (22, 24) with an outer flange surface and an inner flange surface (21, 23) as well as a method for manufacturing the spool. The discs have a central through bore (30) that is surrounded by an annular recess (25) with an annular wall (26) positioned in the inner flange surface. A tubular spool core (10) has front surfaces which are connected in a materially bonded manner to the annular wall (26) inside the annular recess (25) of the flange discs (22, 24), wherein at least one channel (32) is provided next to the annular wall (26) inside the annular recess (25) for receiving liquefied connection material. The spool core (10) has approximately the same diameter as the annular wall (26) inside the annular recess (25).

A method for producing a cable spool including the steps of providing a mold for producing a cable spool, assembling said mold by joining said at least two central mold pieces and said first and second flange mold pieces, adding molten polymer material to said mold, removing said mold and cooling said cable spool. Also, a mold for producing a cable spool, said mold including at least two central mold pieces, a first flange mold piece and a second flange mold piece. Also, a plastic cable spool including a barrel and two annular flanges located at opposite ends of said barrel, wherein each one of said flanges has an inward facing side directed towards said other flange and an outward facing side, and each one of said flanges includes a through-hole extending between said inward facing side and said outward facing side.

A reel includes a core, a first flange affixed to a first end of the core, a second flange affixed to a second opposite end of the core, and a first bonded joint connecting the first flange to the core. The first bonded joint includes a first susceptor material arranged between the first flange and the first end of the core, and the first flange and the first end of the core are bonded around the first susceptor material.