Assembling reels with spring-loaded magnetic guides

Abstract

A method for assembling a reel comprising a first flange, a second flange and a barrel is disclosed. This method comprises (i) securing at least one spring-loaded magnetic guide to a base; (ii) positioning the first flange over the at least one spring-loaded magnetic guide and the base, so that a distal end of the at least one spring-loaded magnetic guide is inserted through a first hole in the first flange, (iii) connecting the barrel to the first flange, (iv) connecting the second flange to the barrel so that the barrel is located between the first and second flanges, (v) inserting at least one threaded fastener through a second hole in the second flange such that a distal end of the at least one threaded fastener is magnetically attached to the distal end of the at least one spring-loaded magnetic guide, and (vi) connecting the at least one threaded fastener to the first flange to form the reel. Also disclosed are the structures of the spring loaded magnetic guide.

Claims

1. A method for assembling a reel comprising a first flange, a second flange and a barrel comprising the steps of (i) securing at least one spring-loaded magnetic guide to a base; (ii) positioning the first flange over the at least one spring-loaded magnetic guide and the base, so that a distal end of the at least one spring-loaded magnetic guide is inserted through a first hole in the first flange, (iii) connecting the barrel to the first flange, (iv) connecting the second flange to the barrel so that the barrel is located between the first and second flanges, (v) inserting at least one threaded fastener through a second hole in the second flange such that a distal end of the at least one threaded fastener is magnetically attached to the distal end of the at least one spring-loaded magnetic guide, and (vi) connecting the at least one threaded fastener to the first flange to form the reel.

2. The method of claim 1, wherein in step (ii) the distal end of the at least one spring-loaded magnetic guide protrudes above a surface of the first flange.

3. The method of claim 1, wherein the at least one threaded fastener comprises a bolt.

4. The method of claim 1, wherein the at least one threaded fastener comprises a screw and step (ii) includes a step of inserting a corresponding nut into the first hole.

5. The method of claim 1, wherein the distal end of the at least one spring-loaded magnetic guide is a distal end of a slidable magnetic body of said guide.

6. The method of claim 1 further comprising the step (vii) of inserting an additional threaded fastener into another second hole in the second flange and connecting the additional threaded fastener to the first flange.

7. The method of claim 1 further comprising the step (vii) of inserting an additional threaded fastener into another first hole in the first flange and connecting the additional threaded fastener to the first flange to the second flange.

8. The method of claim 1 further comprising an alignment guide secured to the base, wherein said alignment guide is also received by the first flange.

9. The method of claim 8, wherein the alignment guide comprises an arbor pin.

10. The method of claim 8, wherein the alignment guide comprises a lug pin.

11. A method for assembling a reel comprising a first flange, a second flange and a barrel comprising the steps of (i) securing at least one magnetic guide to a base; (ii) positioning the first flange over the at least magnetic guide and the base, so that a distal end of the at least one magnetic guide is aligned with a first hole in the first flange, (iii) connecting the barrel to the first flange, (iv) connecting the second flange to the barrel so that the barrel is located between the first and second flanges, (v) inserting at least one threaded fastener through a second hole in the second flange such that a distal end of the at least one threaded fastener is magnetically attached to the distal end of the at least one magnetic guide, and (vi) connecting the at least one threaded fastener to the first flange to form the reel.

12. The method of claim 11, wherein in step (ii) the distal end of the at least one magnetic guide protrudes above a surface of the first flange.

13. The method of claim 11, wherein the at least one threaded fastener comprises a bolt.

14. The method of claim 11, wherein the at least one threaded fastener comprises a screw and step (ii) includes a step of inserting a corresponding nut into the first hole.

15. The method of claim 11 further comprising the step (vii) of inserting an additional threaded fastener into another second hole in the second flange and connecting the additional threaded fastener to the first flange.

16. The method of claim 11 further comprising the step (vii) of inserting an additional threaded fastener into another first hole in the first flange and connecting the additional threaded fastener to the first flange to the second flange.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:

(2) FIG. 1 is a perspective, exploded view of an assembling base, a plurality of spring-loaded magnetic guides, and a first flange, wherein one of the spring-loaded magnetic guide is in an exploded view, and wherein the orientation guides are not fully shown due the angle of the view;

(3) FIG. 2 is a cross-sectional, exploded side view of FIG. 1, showing the orientation guides and the spring-loaded magnetic guides;

(4) FIG. 3(a) is an enlarged side view of one spring-loaded magnetic guide; FIG. 3(b) is an enlarged, exploded view of the spring-loaded magnetic guide; FIG. 3(c) is an enlarged side view of an alternative embodiment of the spring-loaded magnetic guide; and

(5) FIGS. 4-8 show the steps in the inventive method of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(6) The present invention includes, but is not limited to, a method of assembling reels using magnetic guides, and the spring-loaded magnetic guides. As best shown in FIGS. 1-3, one or more spring-loaded magnetic guides 10 are inserted into and held by an assembling base 12. Base 12 defines a number of holes sized and dimensioned to accept spring-loaded magnetic guides 10, as well as, an arbor pin 14 and a lug pin 16. Arbor pin 14 is sized and dimensioned to be received in the arbor or center hole 18 in first flange 20, and lug pin 16 is sized and dimensioned to be received in the off-centered lug hole 22. Arbor pin 14 and lug pin 16 are used for alignment purpose, and when necessary only one pin is preferably used. More preferably, arbor pin 14 is used for alignment of first flange 20 to assembling base 12, as illustrated below.

(7) As best shown in FIGS. 1-2, one or more pin 14 or 16 is inserted into assembly base 10 to stabilize first flange 20. Assembly base 10 is illustrated as a finite rectangular shaped slab. However, assembly base 10 can have any shape and can be a part of assembly line comprising multiple bases 10. Three spring-loaded magnetic guides 10 are shown, but any number of guides 10 can be used. Guides 10 are inserted into base 12, and after first flange 10 is positioned above base 12, guides 10 are inserted through corresponding bolt-receiving holes 24 and preferably protrude therethrough, as shown below.

(8) As best shown in FIGS. 3(a)-(b), a spring-loaded magnetic guide 10 comprises a hollow tubular housing 26 with a retaining end 28 and an open end 30. Tubular housing 26 stores a spring, preferably a helical spring therewithin. Retaining end 28 retains the spring and the open end 30 is adapted to receive a slidable subassembly 32, comprising a shoulder 34 and a sliding magnetic body 36 capable of sliding relative to shoulder 34. Magnetic body 36 also has an enlarged head 38 sized and dimensioned to compress the spring inside tubular body 26, and shoulder 34 is attached to open end 30 of tubular body 26. The diameter of shoulder 34 is larger than that of open end 30, so that magnetic body 36 can slide into and out of tubular body 26. When magnetic body 36 slides inside tubular body 36, enlarged head 38 compresses the spring. Distance l is the distance that the spring would compress during the reel assembling process, and is sufficient for the magnetic body 36 to move downward to clear first flange 20.

(9) In another embodiment, an optional magnetic disk 40 is provided, preferably located above shoulder 34, as shown in FIG. 3(c). Magnetic disk 40 provides an additional magnetic field to attract the distal end of connecting bolts or screws toward distal end 42 of magnetic body 38.

(10) FIG. 4 illustrates the configuration showing first flange 20 being positioned above assembling base 12. Arbor pin 14 is inserted through arbor hole 18 of first flange 20 to help align first flange 12, as well as providing structural support for first flange 20 during the assembling process. The distal ends of sliding magnetic body 36 protrude through the bolt-receiving holes 24.

(11) In the next step, a barrel 44 is inserted into route groove 46, which is a circular groove located concentrically outside of arbor hole 18, as illustrated in FIG. 5. In the next step, second flange 48, which is preferably substantially similar to or the same as first flange 20, is positioned on top of barrel 44 in a similar fashion, as shown in FIG. 6. The bolt-receiving holes in second flange 48 only need to be roughly aligned with the bolt-receiving holes in first flange 20. The same number of bolts 50 as the number of guides 10 is inserted into bolt-receiving holes 24 on second flange 48, as illustrated in FIG. 7. Bolts 50, in this embodiment, are shown partially in FIGS. 4 and 5, and in addition to having a bolt head has a threaded distal end and a smooth shaft. In other words, in this embodiment bolts 50 are lagging bolts that after assembling tend to pull the first and second flanges together.

(12) When bolts 50 are inserted, their distal ends are attracted and pulled by the magnetic field/force emanating from slidable magnetic body 36 and/or magnetic disc 40. This magnetic force also aligns bolts 50 to slidable magnetic body 36. As bolts 50 and magnetic bodies 36 make contact, they typically produce a metallic clicking sound informing the operator of the connection. As bolts 50 are advanced by rotation into first flange 20, as illustrated in FIG. 8, the distal ends of bolts 50 push the distal ends of slidable magnetic body 36 against the spring into tubular body 26 of spring-loaded magnetic guide 10. The amount of compression of the spring, labeled as l in FIG. 3(a), is sufficient for the distal end of bolts 50 to threadedly connect to first flange 20 to complete the assembling of the reel.

(13) As illustrated in FIGS. 4-8, first and second flanges 20 and 48 have six bolt-receiving holes, although the present invention is not limited to any number of holes or bolts, and as illustrated three bolts 50 were used. Any number of bolts can be used so long as the first and second flanges are securely attached. Preferably, each bolt-receiving hole receives a bolt 50. More preferably, some bolts are inserted through second flange 48, as illustrated, and some bolts are inserted through first flange 20, e.g., by inverting the reel, placing second flange 48 on assembling base 10 with the protruding spring-loaded, magnetic guides 10 and repeat the process.

(14) In another embodiment, bolts 50 are replaced by screws 50 of the same length and diameter and nuts that can be threaded onto the distal ends of the screws. The nuts can be inserted into the bolt-receiving holes on the first flange, and slidable magnetic body 36 of guides 10 can protrude through the nuts and are freely movable relative to the nuts. As the screws 50 advance by rotation, the screws displace the slidable magnetic body 36 and are threaded to the nuts to complete the assembly of the reels.

(15) The present invention eases and speeds up the assembly process by facilitating the alignment between the distal ends of the bolts/screws with the bolt-receiving holes/nuts. The present invention also negates the need for the technicians or assemblers to search for the holes or feel for the holes with the distal end of the bolts/screws.

(16) Preferably, flanges 20, 48 are made from plastics, such as thermoplastics and more preferably from molded plastics. Barrel 44 can be made from paper, plastics (thermoplastics or thermosets) or metal (non-ferrous or ferrous). Flanges 20, 48 can also be made from thicker plywood. The magnetic guides could be sized and dimensioned to be used with plywood and/or the magnetic field can be increased to attract the bolts/screws.

(17) While it is apparent that the illustrative embodiments of the invention disclosed herein fulfill the objectives stated above, it is appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which would come within the spirit and scope of the present invention.