CABLE REEL WITH AXIALLY ADJUSTABLE COUPLING MECHANISM

Abstract

A cable reel is described. The cable reel includes first and second opposing flanges. The first flange has a first hub portion and the second flange has a second hub portion. The first and second hub portions are configured to be axially aligned and configured to mate with one another to support cable. The cable reel includes an axially adjustable coupling mechanism configured to couple the first hub portion to the second hub portion at a plurality of stable axial positions. The first hub portion is rotationally fixed to the second hub portion at the plurality of axial positions.

Claims

1. A cable reel, comprising: first and second opposing flanges, the first flange having a first hub portion and the second flange having a second hub portion, the first and second hub portions configured to be axially aligned and configured to mate with one another to support cable; and an axially adjustable coupling mechanism configured to couple the first hub portion to the second hub portion at a plurality of stable axial positions, wherein the first hub portion is rotationally fixed to the second hub portion at the plurality of axial positions.

2. The cable reel of claim 1, the first hub portion including an elongated wall extending from the first flange, the elongated wall being sized to support cable, the elongated wall defining an inner area configured to accept the second hub portion, and the elongated wall including a plurality of flexible segments; and the second hub portion including a truncated wall receivable in the inner area of the first hub portion, said truncated wall including a tapered outer surface for engaging and expanding the plurality of flexible segments.

3. The cable reel of claim 1, wherein the axially adjustable coupling mechanism includes a threaded connection.

4. The cable reel of claim 3, wherein the axially adjustable coupling mechanism includes a ratcheting pawl.

5. The cable reel of claim 1, wherein the axially adjustable coupling mechanism includes at least one axial spline and complementary axial slot.

6. The cable reel of claim 1, wherein the axially adjustable coupling mechanism includes a plurality of recesses, wherein at least two of the recesses of the plurality of recesses are located at different axial positions, and at least one radially-biased flexible arm configured to engage with at least one recess of the plurality of recesses.

7. The cable reel of claim 6, wherein the at least one recess is a circumferential recess around one of the first hub portion or the second hub portion.

8. The cable reel of claim 1, wherein the axially adjustable coupling mechanism includes a plurality of flexible arms, wherein at least two of the flexible arms of the plurality of flexible arms have a protrusion located at different axial positions, and at least one recess is configured to receive a protrusion.

9. The cable reel of claim 8, wherein a first arc length of at least one protrusion is substantially equal to a second arc length of a recess.

10. The cable reel of claim 8, wherein at least one flexible arm of the plurality of flexible arms has a plurality of protrusions protruding therefrom.

11. The cable reel of claim 1, wherein the first hub portion is longer than the second hub portion in the axial direction.

12. The cable reel of claim 1, further comprising first and second support frames rotatably coupled to the first hub portion and second hub portion, respectively.

13. The cable reel of claim 12, wherein each of the first and second flanges is substantially disc shaped.

14. The cable reel of claim 12, further comprising a braking mechanism configured to limit rotation of at least one of the first flange and second flange relative to the first support frame.

15. A method of installing a cable coil on a cable reel, the method comprising: providing a first flange of the cable reel, wherein the first flange has a first hub portion connected thereto; positioning a cable coil on the first hub portion and contacting the first flange; coupling the first hub portion to a second hub portion by an axially adjustable coupling mechanism; and moving the second hub portion through a plurality of stable axial positions of the axially adjustable coupling mechanism until a second flange contacts the cable coil.

16. The method of claim 15, wherein coupling the first hub portion to a second hub portion by an axially adjustable coupling mechanism includes rotating the second hub portion relative to the first hub portion.

17. The method of claim 15, wherein coupling the first hub portion to a second hub portion by an axially adjustable coupling mechanism includes moving the second hub portion axially relative to the first hub portion without rotating the second hub portion relative to the first hub portion.

18. A cable reel kit, the kit comprising: a first flange including a first hub portion, wherein the first hub portion includes a first part of an axially adjustable coupling mechanism; and a second flange having a second hub portion, wherein the first hub portion includes a second part of an axially adjustable coupling mechanism and the first part and the second part of the axially adjustable coupling mechanism are configured to mate to provide a plurality of stable axial positions of the axially adjustable coupling mechanism.

19. The kit of claim 18, further comprising a first support frame and a second support frame configured to support the first flange and the second flange, respectively, wherein the first support frame and second support frame are configured to allow the first flange and second flange to rotate freely relative to the first support frame and the second support frame.

20. The kit of claim 19, further comprising a cover configured to cover the first support frame, the second support frame, the first flange and the second flange.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0081] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: The accompanying drawings are incorporated in and constitute a part of this specification. It is to be understood that the drawings illustrate only some examples of the disclosure and other examples or combinations of various examples that are not specifically illustrated in the figures may still fall within the scope of this disclosure. Examples will now be described with additional detail through the use of the drawings, in which:

[0082] FIG. 1 is a perspective view of a cable reel in accordance with an exemplary embodiment of the present invention, shown with a supporting bag or box, according to at least one embodiment of the present disclosure;

[0083] FIG. 2 is a perspective view of a support frame of the cable reel illustrated in FIG. 1;

[0084] FIG. 3 is an elevational view of a flange of the cable reel illustrated in FIG. 1,

[0085] FIG. 4A is a perspective view of a first hub portion of the cable reel illustrated in FIG. 1;

[0086] FIG. 4B is a partial perspective view of the first hub portion illustrated in FIG. 4A, showing the hub in cross-section;

[0087] FIG. 5A is an elevational view of a second hub portion of the cable reel illustrated in FIG. 1;

[0088] FIG. 5B is a perspective view of the second hub portion of the cable reel illustrated in FIG. 5A;

[0089] FIG. 6 is an enlarged partial perspective view of the frame illustrated in FIG. 2, showing outer gears of the frame;

[0090] FIG. 7 is an enlarged partial side elevational view of the flange illustrated in FIG. 3, showing the inner gears of the flange;

[0091] FIG. 8 is an enlarged side elevational view of the frame and the flange of the cable reel illustrated in FIG. 1, showing the inner and outer gears engaged;

[0092] FIG. 9 is a side view of a cable reel with an axially adjustable coupling mechanism with a threaded connection, according to at least one embodiment of the present disclosure;

[0093] FIG. 10 is a side cross-sectional view of the cable reel with an axially adjustable coupling mechanism with a threaded connection of FIG. 9;

[0094] FIG. 11 is a side partial cross-sectional view of a cable reel with an axially adjustable coupling mechanism with a rotational ratcheting mechanism, according to at least one embodiment of the present disclosure;

[0095] FIG. 12 is a side partial cross-sectional view of a cable reel with an axially adjustable coupling mechanism with an axial ratcheting mechanism, according to at least one embodiment of the present disclosure;

[0096] FIG. 13 is a side cross-sectional view of a cable reel with an axially adjustable coupling mechanism with a threaded connection to a nut, according to at least one embodiment of the present disclosure;

[0097] FIG. 14 is a detail cross-sectional view of a cable reel with an axially adjustable coupling mechanism with a splined snap connection, according to at least one embodiment of the present disclosure;

[0098] FIG. 15 is a side cross-sectional view of a cable reel with an axially adjustable snap connection with a plurality of sets of recesses (e.g., engagement recesses), according to at least one embodiment of the present disclosure;

[0099] FIG. 16 is a side cross-sectional view of a cable reel with an axially adjustable snap connection with different length snap arms, according to at least one embodiment of the present disclosure; and

[0100] FIG. 17 is a side cross-sectional view of a cable reel with an axially adjustable snap connection with a plurality of sets of protrusions on snap arms, according to at least one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0101] The present disclosure relates to a method of installing a coil of cable in a bag, that comprises the steps of: placing a coil of cable on a first hub of a first flange of a cable reel; placing a second flange of the cable reel, that is separable from the first flange, opposite from the first flange to hold the coil of cable on the first hub of the first flange; positioning the first flange on or next to a first support frame received in the bag; and placing the second flange on or next to a second support frame received in the bag. The second support frame is positioned in the bag such that the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame.

[0102] The present disclosure relates to a method of installing a coil of cable in a bag, that comprises the steps of: placing a coil of cable on a first hub of a first flange of the cable reel; placing a second flange of the cable reel opposite from the first flange to hold the coil of cable on the first hub of the first flange; positioning the first flange on or next to a first support frame located in the bag; and placing the second flange on or next to a second support frame located in the bag, wherein the second support frame is positionable in the bag such that the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame. The step of placing the coil of cable on the first hub of the first flange occurs before the step of positioning the first flange on the first support frame.

[0103] The present disclosure relates to a method of installing a coil of cable in a bag, the bag having a cover for opening the bag, a base opposite the cover, and sides extending between the cover and the base, the method comprising the steps of: placing a coil of cable on a first hub of a first flange of a cable reel; placing a second flange of the cable reel, that is separable from the first flange, opposite from the first flange to hold the coil of cable on the first hub of the first flange; positioning the first flange on or next to a first support frame received in the bag, the first support frame being on an inner surface of the base of the bag; and placing the second flange on or next to a second support frame received in the bag, the second support frame being on an inner surface of the cover of the bag. When the cover of the bag is closed, the first flange, the coil of cable and the second flange are located between the first support frame and the second support frame inside the bag.

[0104] Referring to FIGS. 1-3, 4A, 4B, 5A, 5B, and 6-8, the present invention relates to a cable reel 100 that may be carried in a conventional shoulder bag or satchel, a card-board or plastic box 101, and the like, with an opening 103 for easy payout of cable supported on the cable reel. The cable reel 100 according to an exemplary embodiment of the present invention is designed to provide easy installation of cable C, such as a cable coil, on the reel 100 and also prevents overpayout of the cable. Because the cable reel 100 is designed to be carried by an installer, it is preferable that the components of the cable reel 100 be formed of lighter weight materials, such as plastic. Some exemplary plastic materials include polyethylene, polypropylene, ABS, or other polymer products.

[0105] As seen in FIG. 1, the cable reel 100 generally includes opposing support frames 102 and 104 that rotatably support first and second flanges 106 and 108 with a hub member 110 therebetween on which the cable is held. A braking mechanism 112 is preferably provided on the reel 100 between the support frames 102 and 104 of the flanges 106 and 108 to limit overpayout of the cable. The cable reel 100 may be inserted into and supported by the payout bag or box wherein the support frames 102 and 104 are attached, preferably removably attached, to the cover and base, respectively, of the bag.

[0106] As seen in FIGS. 2 and 6, each support frame 102 and 104 includes an outer frame portion 120 with one or more cross members 122 and a middle flange support 124. The outer frame portion 120 may have a substantially square geometry. The middle flange support 124 includes an annular extension 126 (FIG. 6) that supports a first part of the braking mechanism 112. The first part of the braking mechanism may be an outwardly extending gear member 128 that includes a plurality of annularly arranged teeth 130 extending radially outwardly from the annular extension 126.

[0107] The middle flange support 124 and gear member 128 are offset or off-center on the frame such that the distance d1 (FIG. 2) to one end 132 of the frame is longer than the distance d2 (FIG. 2) to the opposite end 135 of the frame. This offset provides a gap 134, as seen in FIG. 8, in the braking mechanism 112. Indicia 136, such as a company name, may be provided on the end 132 of the frame to indicate the longer side, which is distance d1 of the frame to facilitate the orientation of the cable reel 100 in the bag or box.

[0108] Each flange 106 and 108 is preferably sized to fit within the outer frame portion 120 of its respective support frame 102 and 104 and is sized to accommodate the cable such as a cable coil. The cable coil may, for example, have an outer diameter of 345 mm and an inner diameter of 200 mm and a height of 135 mm. The flanges 106 and 108 are preferably disc-shaped. Each flange has inner and outer surfaces 140 and 142 and a central arbor opening 144. The inner surface 140 of each flange abuts the hub member 110 and the outer surface 142 abuts a respective support frame 102 and 104.

[0109] The central arbor opening 144 corresponds to the middle flange support 124 of each respective support frame. The central arbor opening 144 supports the second part of the braking mechanism 112 as seen in FIGS. 3 and 7. The second part of the braking mechanism 112 may be an internal gear member 146 that includes a plurality of annular arranged teeth 148 extending radially inwardly.

[0110] The hub member 110 is located between the flanges 106 and 108 and supports the cable coil. The hub member 110 includes a first hub portion 150 (FIGS. 4A and 4B) and a second hub portion 152 (FIGS. SA and 5B) that are axially aligned and configured to mate with one another. The hub portions 150 and 152 may be formed separately from the respective flanges 106 and 108 and attached thereto or the hub portions 150 and 152 may be formed as one-piece with the respective flanges 106 and 108.

[0111] As seen in FIGS. 4A and 4B, the first hub portion 150 is preferably the base of the cable reel and provides the main support for the cable. As such, the first hub portion 150 is larger than the second hub portion 152. The first hub portion 150 includes an elongated wall 154 that extends from the inner surface 140 of the first flange 106 and defines an inner area 156 that receives the second hub portion 152. The elongated wall 154 has a tapered outer surface 158 that tapers inwardly from the flange inner surface 140 to the free end 160 of the wall 154. Slots 162 in the elongated wall 154 create flexible segments 164, which engage both the second hub portion 152 and the cable coil to retain the same. A groove 166 (FIG. 4B) may be located at the base of the elongated wall 154 to provide additional flexibility to the segments 164. Any other mechanism may be provided to add flexibility to the segments 164. For example, the segments 164 can be made thinner.

[0112] Secondary engagement members 170 may be provided as a back-up to retain the hub portions 150 and 152 together. The secondary engagement members 170 may be, for example, one or more snap arms 172 provided in the inner area 156 that extend from the flange inner surface 140. The one or more snap arms 172 preferably extend beyond the elongated wall 154 of the first hub portion 150, as seen in FIG. 4A, in order to engage the second flange 108. The ends of the snap arms 172 preferably include snap tabs 174 that engage corresponding slots 176 (FIG. 5B) in the second flange 108. Although a snapping engagement is preferred to secure the hub portions 150 and 152 together, any known interlocking mechanism may be used.

[0113] As seen in FIGS. 5A and 5B, the second hub portion 152 includes a truncated wall 180 that extends from the inner surface 140 of the second flange 108. The truncated wall 180 has a tapered outer surface 182 that fits inside of the elongated wall 154 of the first hub portion 150 to form a friction fit between the hub portions 150 and 152 and expands the flexible segments 164 of the first hub portion 150.

[0114] As seen in FIG. 8, the braking mechanism 112 is provided by meshing the teeth 130 and 148 of the outer and internal gear members 128 and 146. The gap 134 between the teeth 130 and 148 provides clearance for the teeth to slip or jump when the cable is pulled from the reel. The gear members 128 and 146 prevent overpayout of the cable. More specifically, when the cable is pulled from the reel, the flanges 106 and 108 rotate, thereby making the gear teeth 130, 148 rotate. The side support is preferably fixed inside of the supporting bag or box and therefore does not rotate. This causes the gear teeth 148 to override meshing gear teeth 130 on the side support which creates friction and provides a braking to the momentum of the reel if the cable is pulled too hard. This action also creates a clicking mechanism which in turn prevents overpaying the cable.

[0115] The distance of the gap need only be long enough to provide a clearance to have gear teeth 148 to override teeth 130, thereby allowing the braking mechanism to work. This clearance distance could vary depending upon the gear teeth depth, flange hole inner diameter, side support gear depth, and the outer diameter of the middle flange support 124. The gap 134 may be, for example, abut ¾ inch.

[0116] To install the cable on the cable reel 100, the cable coil C is placed over the first hub portion 150 of the hub member 110 and on the first flange 106 so that the first hub portion 150 extends through the inner diameter of the cable coil. The cable coil C may be prepacked in a plastic shrink wrap or with tie wraps or combination of both without any external structure to support that coil. Next the second hub portion 152 is inserted inside of the first hub portion 150 to frictionally engage the same and expand the flexible segments 164, thereby forcing the flexible segments 164 to engage the inner diameter of the cable coil. The locking tabs 174 are then inserted inside of the slots 176 on the second flange 108 to hold the two flanges and hub portions together.

[0117] In an example of the present disclosure, the first support frame 102 of the reel 100 is secured to the base of the bag or box, such as by straps, such as via strap 105 (FIG. 1), and the second support frame 104 is secured to the cover or flap of the bag. With the cable coil installed on the hub member 110, the cable coil is inserted into the bag or box between the support frames 102 and 104 in the bag or box. The assembly of the hub portions 150 and 152, the flanges 106 and 108, and the cable coil is preferably inserted into the base of the bag on its side such that the middle flange support 124 of the frame secured to the base of the bag fits inside of the central arbor opening 144 of the flange. Similarly, the middle flange support 124 of the frame secured to the cover of the bag fits inside of the opening 144 of the other flange when the bag is closed. Once the frames 102 and 104 are mated with the flanges 106 and 108, respectively, the operator can then dispense or payout the cable through a cable payout slot or opening in the bag or box. The operator may open the cover of the bag or box to separate the hub portions 150 and 152 by disengaging the snap tabs 174.

[0118] Referring now to FIG. 9, in some embodiments, a cable reel includes an axially adjustable coupling mechanism 284 between the first flange 206 and second flange 208. In particular, the first hub portion 250 and second hub portion 252 are coupled to one another by the axially adjustable coupling mechanism 284. For example, the first hub portion 250 and second hub portion 252 are coupled together along a rotational axis 286 around which the first flange 206 and second flange 208 rotate when in a cable reel assembly, such as that described in relation to FIG. 1 through FIG. 8. The axially adjustable coupling mechanism 284 allows the first hub portion 250 and the second hub portion 252, and therefore the first flange 206 and second flange 208, respectively, to be rotationally fixed to one another at a plurality of axial positions in the direction of the rotational axis 286.

[0119] In some embodiments, the axially adjustable coupling mechanism 284 includes a threaded connection between the first hub portion 250 and the second hub position 252. The axially adjustable coupling mechanism 284 includes a male threaded portion 288 and a complementary female threaded portion 290 on each of the first hub portion 250 and second hub portion 252 respectively, as shown in FIG. 10. In other embodiments, the male threaded portion 288 and the complementary female threaded portion 290 may be located in other configurations, such as the male threaded portion 288 and the complementary female threaded portion 290 positioned on the second hub portion 252 and the first hub portion 250, respectively.

[0120] The first flange 206 and the second flange 208 are configured to contain a coil of cable around the mated first hub portion 250 and second hub portion 252. In some instances, the cable coil can loosen or expand during shipping, during removal from packaging, during installation on the reel, or for other reasons. When the cable coil expands in a traverse direction (e.g., the axial direction of the rotational axis of the cable reel when the cable coil is on the cable reel), the cable coil may be unable to fit between the first flange and the second flange of some cable reels. A cable reel with an axially adjustable coupling mechanism 284 can, therefore, ease the installation of a cable coil when the coil has expanded during shipping, during removal from packaging, during installation on the reel, or for other reasons.

[0121] When a threaded connection is mated together, the first flange 206 and second flange 208 may apply an axially compressive force to the cable coil and/or the first hub portion may apply a radially expansive force to the cable coil. The resulting friction in the threaded connection and/or between the flanges 206, 208 and/or hub portions 250, 252 with the cable coil may secure the axially adjustable coupling mechanism 284. Because the flanges 206, 208 rotate relative to the support frames (such as those described in relation to FIG. 1) substantially freely, the axially adjustable coupling mechanism 284 may remain mated. In embodiments with a braking mechanism, the threads may be oriented in the rotational direction of cable feed from the coil, causing torque applied to the flanges 206, 208 while an installer pulls on the cable to feed out from the cable coil to further tighten the threaded connection.

[0122] Referring now to FIG. 11, in some embodiments, an axially adjustable coupling mechanism 384 includes a rotational ratcheting mechanism (e.g., ratcheting pawls 392 and a plurality of teeth 394) to limit and/or prevent the axially adjustable coupling mechanism 384 from becoming disconnected. The axially adjustable coupling mechanism 384 includes a threaded connection, similar to the structures described in relation to FIG. 10, with ratcheting pawls 392 supported by flexible arms 364 on the first hub portion 350. In some embodiments, the pawls 392 engage with a plurality of teeth 394 or recesses on the second hub portion 352 arranged rotationally around the second hub portion 352. As the threaded connection couples the first hub position 350 to the second hub portion 352, the ratcheting pawls 392 contact and engage with the teeth 394. The flexible arms 364 elastically deform and apply a radially compressive force to the teeth 394 and limit and/or prevent the first hub portion 350 and second hub portion 352 rotating relative to one another and the axially adjustable coupling mechanism 384 becoming disconnected.

[0123] It should be understood that the pawls 392 and teeth 394 may be arranged in other configurations to rotationally engage. For example, the pawls 392 may be supported by the second hub portion 352 and the teeth 394 located on the first hub portion 350. In some embodiments, the pawls 392 may be biased radially outwardly to apply a radially expansive force to teeth 394 oriented toward the rotational axis 386.

[0124] Referring now to FIG. 12, in some embodiments, an axially adjustable coupling mechanism 484 includes an axial ratcheting mechanism to limit and/or prevent the axially adjustable coupling mechanism 484 from becoming disconnected. The axially adjustable coupling mechanism 484 includes a threaded connection, similar to the structures described in relation to FIG. 10, with ratcheting pawls 492 supported by flexible arms 464 on the first hub portion 450. In some embodiments, the pawls 492 engage with a plurality of teeth 494 or recesses on the second hub portion 452 arranged axially on the second hub portion 452. As the threaded connection couples the first hub position 450 to the second hub portion 452, the ratcheting pawls 492 contact and engage with the teeth 494. The flexible arms 464 elastically deform and apply a radially compressive force to the teeth 494 and limit and/or prevent the first hub portion 450 and the second hub portion 452 from moving axially relative to one another and the axially adjustable coupling mechanism 484 becoming disconnected.

[0125] It should be understood that the pawls 492 and teeth 494 may be arranged in other configurations to axially engage. For example, the pawls 492 may be supported by the second hub portion 452 and the teeth 494 located on the first hub portion 450. In some embodiments, the pawls 492 may be biased radially outwardly to apply a radially expansive force to teeth 494 oriented toward the rotational axis 486.

[0126] While embodiments of axially adjustable coupling mechanisms with threaded connections have been described with the threads on the first hub portion and the second hub portion, in other embodiments, an axially adjustable coupling mechanism with a threaded connection includes a nut or other additional component to compress the first hub portion to the second hub portion.

[0127] FIG. 13 is a side cross-sectional view of an embodiment of a first hub portion 550 and a second hub portion 552 that are connected by an axially adjustable coupling mechanism 584 including a nut 596. In some embodiments, the male threaded portion 588 is positioned on the first hub portion 550 and the complementary female threaded portion 590 is positioned on the nut 596 opposite the second hub portion 552. A part of the first hub portion 550 may be inserted through the second hub portion 552 to engage with the nut 596. When the male threaded portion 588 on the first hub portion 550 engages with the complementary female threaded portion 590 positioned on the nut 596, the threaded connection compresses the second hub portion 552 against the first hub portion 550. In some embodiments, the second hub portion 552 and/or second flange 508 is configured to receive the nut 596 flush with a surface of the second hub portion 552 and/or second flange 508. The first flange 506 and second flange 508 may fit within the support frames of the reel when the nut 596 and second flange 508 form a flat outer surface.

[0128] Other embodiments of axially adjustable coupling mechanisms do not include threads, but rather rotationally and/or axially fix the first hub portion relative to the second hub portion through axially oriented splines. FIG. 14 is a detail cross-sectional view of an axially adjustable coupling mechanism 684 with axial splines 696. An axial spline 696 on the second hub portion 652 engages with an axial slot 698 on the first hub portion 650 and, alone, limits and/or prevents rotation of the first hub portion 650 and the second hub portion 652 relative to one another while allowing axial movement relative to one another.

[0129] In some embodiments, one or more radial protrusions 699 on flexible arms 664 of the first hub portion 650 may engage with one or more circumferential recesses 607 on the second hub portion 652. The engagement of the radial protrusion 699 and circumferential recess 607 alone limits and/or prevents axial movement of the first hub portion 650 and the second hub portion 652 relative to one another while allowing rotational movement relative to one another. When an axially adjustable coupling mechanism 684 includes both the spline(s) 696 and slot(s) 698 with the protrusion(s) 699 and recess(es) 607, the axially adjustable coupling mechanism 684 both rotationally and axially fixes the first hub portion 650 relative to the second hub portion 652. The flexible arms 664 supporting the protrusions 699 may elastically deform allowing an installer to press the first hub portion 650 and second hub portion 652 together and pull the first hub portion 650 and second hub portion 652 apart, while still providing sufficient force to prevent unintended decoupling.

[0130] FIG. 15 through FIG. 17 illustrate embodiments of axially adjustable coupling mechanisms that provide a plurality of discrete axial positions. FIG. 15 is a side cross-sectional view of an embodiment of a first hub portion 750 and a second hub portion 752 with an axial series of recesses 707-1, 707-2, 707-3. The recesses 707-1, 707-2, 707-3 of the second hub portion 752 are positioned in a series of sets of recesses 707-1, 707-2, 707-3. The first recesses 707-1 include a set of recesses at a first axial position. The first recesses 707-1 include a set of recesses at a first axial position. The first recesses 707-1 include a set of recesses at a first axial position. The each set of recesses 707-1, 707-1, 707-3 includes a plurality of recesses complementarily formed to the protrusions 799 of the axially adjustable coupling mechanism 784.

[0131] The axially adjustable coupling mechanism 784 includes a plurality of flexible snap arms 772 with protrusions 799 protruding radially therefrom. The arms are elastically deformable to apply a radially outward force to the urge the protrusions toward one of the sets of recesses 707-1, 707-2, 707-3 as the first hub portion 750 is urged toward the second hub portion 752. In some embodiments, the protrusions 799 engage with a set of the recesses 707-1, 707-2, 707-3 in sequence as the first hub portion 750 moves axially. The engagement of the protrusions 799 with each set of recesses 707-1, 707-2, 707-3 provides a series of stable axial positions for the first hub portion 750 relative to the second hub portion 752. For example, a stable axial position may be a low energy state. For instance, when a protrusion 799 is at a stable axial position in a recess 707-1, 707-2, 707-3, additional force is required to move the protrusion 799 from the recess 707-1, 707-2, 707-3. In another example, a stable axial position may include a position where the force required for a protrusion 799 to engage a recess 707-1, 707-2, 707-3 may be lower than the force required to remove the protrusion 799 from the recess 707-1, 707-2, 707-3.

[0132] The protrusions 799 engage with each set of recesses 707-1, 707-2, 707-3 to limit and/or prevent movement of the first hub portion 750 relative to the second hub portion 752 in both the axial and the rotational directions. In some embodiments, the protrusions have a ramped surface in an axial direction to allow the protrusions to move out of the sets of recesses 707-1, 707-2, 707-3 in the axial direction when sufficient force is applied by an installer. In some embodiments, the protrusions 799 are ramped in the direction of the second flange 708 to ease connection and/or ramped in the direction of the first flange 706 to ease removal. In some embodiments, a slope of the ramped surface may be different on a leading face than on a trailing face (e.g., a leading face may have a lower slope to facilitate a protrusion 799 engaging a recess 707-1, 707-2, 707-3 as the protrusion 799 slides toward the second hub 752 along and a trailing face may have a higher slope to facilitate the protrusion 799 remaining in the recess 707-1, 707-2, 707-3 as the protrusion 799 is pulled away from the second hub 752).

[0133] In some embodiments, protrusions positioned at a variety of axial positions can sequentially engage with a single set of recesses to provide a plurality of stable axial positions for an axially adjustable coupling mechanism. FIG. 16 is a side cross-sectional view of an embodiment of a first hub portion 850 and a second hub portion 852 with a plurality of protrusions 899-1, 899-2 at different axial positions. The protrusions 899-1, 899-2 are supported by flexible snap arms 872 of different or equal lengths with each set of protrusions 899-1, 899-2 at a terminal end of the flexible snap arms 872 or in an intermediate location between a base of the flexible snap arms 872 and the terminal end.

[0134] In some embodiments, the angular arc length of a protrusion 899-1, 899-2 is substantially equal to that of the recess 807 into which the protrusion 899-1, 899-2 engages. For example, a protrusion 899-1, 899-2 with an arc length of 10° around the rotational axis may fit into a recess 807 of approximately a 10° arc length. By having complementary arc lengths, the protrusion 899-1, 899-2 and recess 807 limit and/or prevent the rotational movement of the first hub portion 850 relative to the second hub portion 852. In some embodiments, the protrusion 899-1, 899-2 has an arc length less than that of the recess to relax manufacturing tolerances and ease engagement between the protrusion 899-1, 899-2 and the recess 807.

[0135] As the first hub portion 850 is urged toward the second hub portion 852, the flexible snap arms 872 contact an inner surface of the second hub portion 852 and elastically deform radially. The first set of protrusions 899-1 approach the set of recesses 807 in the second hub portion 852. When the first set of protrusions 899-1 align axially and rotationally with at least some of the recesses of the set of recesses 807, the first set of protrusions 899-1 may engage (due to an elastic restorative force from the flexible snap arms 872) with the set of recesses 807 at a first axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 850 relative to the second hub portion 852.

[0136] An installer may apply a force to further disengage the first set of protrusions 899-1 from the set of recesses 807 and urge the second set of protrusions 899-1 toward the set of recesses 807. In some embodiments, when the second set of protrusions 899-2 align axially and rotationally with at least some of the recesses of the set of recesses 807, the second set of protrusions 899-2 may engage (due to an elastic restorative force from the flexible snap arms 872) with the set of recesses 807 at a second axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 850 relative to the second hub portion 852.

[0137] FIG. 16 illustrates an embodiment of an axially adjustable coupling mechanism 884 with a plurality of flexible snap arms 872 of different lengths with protrusions 899-1, 899-2 located at a terminal end thereof. In other embodiments, at least one of the flexible snap arms has a plurality of protrusions to provide different stable axial positions for the axially adjustable coupling mechanism. For example, FIG. 17 is a side cross-sectional view of an embodiment of a first hub portion 950 and a second hub portion 952 with an axial series of protrusions 999-1, 999-2 on at least one flexible snap arm 972.

[0138] The first set of protrusions 999-1 are located at a first axial position on the flexible snap arms 972. The second set of protrusions 999-2 are located at a second axial position on the flexible snap arms 972. The two sets of protrusions 999-1, 999-2 are configured to engage with the set of recesses 907 in the second hub portion 952 when the first hub portion 952 and second hub portion 950 are urged toward one another.

[0139] When the first set of protrusions 999-1 align axially and rotationally with at least some of the recesses of the set of recesses 907, the first set of protrusions 999-1 may engage (due to an elastic restorative force from the flexible snap arms 972) with the set of recesses 907 at a first axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 950 relative to the second hub portion 952.

[0140] An installer may apply a force to further disengage the first set of protrusions 999-1 from the set of recesses 907 and urge the second set of protrusions 999-1 toward the set of recesses 907. In some embodiments, when the second set of protrusions 999-2 align axially and rotationally with at least some of the recesses of the set of recesses 907, the second set of protrusions 999-2 may engage (due to an elastic restorative force from the flexible snap arms 972) with the set of recesses 907 at a second axial position to limit and/or prevent unintended rotational and/or axial movement of the first hub portion 850 relative to the second hub portion 952.

[0141] While particular embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. It will be apparent to those skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings that modifications, combinations, sub-combinations, and variations can be made without departing from the spirit or scope of this disclosure. Likewise, the various examples described may be used individually or in combination with other examples. Those skilled in the art will appreciate various combinations of examples not specifically described or illustrated herein that are still within the scope of this disclosure. In this respect, it is to be understood that the disclosure is not limited to the specific examples set forth and the examples of the disclosure are intended to be illustrative, not limiting.

[0142] As used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents, unless the context clearly dictates otherwise. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “comprising,” “including,” “having” and similar terms are intended to be inclusive such that there may be additional elements other than the listed elements.

[0143] Additionally, where a method described above or a method claim below does not explicitly require an order to be followed by its steps or an order is otherwise not required based on the description or claim language, it is not intended that any particular order be inferred. Likewise, where a method claim below does not explicitly recite a step mentioned in the description above, it should not be assumed that the step is required by the claim.

[0144] It is noted that the description and claims may use geometric or relational terms, such as right, left, above, below, upper, lower, top, bottom, linear, arcuate, elongated, parallel, perpendicular, etc. These terms are not intended to limit the disclosure and, in general, are used for convenience to facilitate the description based on the examples shown in the figures. In addition, the geometric or relational terms may not be exact. For instance, walls may not be exactly perpendicular or parallel to one another because of, for example, roughness of surfaces, tolerances allowed in manufacturing, etc., but still be considered to be perpendicular or parallel.