Reel Having Flange with Sustainable Fasteners

Abstract

A reel has first and second flanges formed of a wood-based material and having annular channels, and a plurality of staves. Each stave extends between the annular channels of the opposing first and second flanges. At least a first stave is secured in at least one of the first annular channel or the second annular channel. The plurality of staves collectively form at least one core surface around which flexible material may be wound between the first flange and the second flange. The reel also includes a plurality of fasteners formed primarily of a wood-based or plastic material, each extending through a portion of the first flange and a corresponding one of the plurality of staves.

Claims

1. A reel, comprising: a first flange including at least a first plate formed of a wood-based material, the first flange having a first annular channel; a second flange having including at least a first plate formed of a wood-based material. the second flange having a second annular channel; a plurality of staves, each stave extending from within the first annular channel to within the second annular channel, at least a first stave secured in at least one of the first annular channel or the second annular channel, the plurality of staves collectively form at least one core surface around which flexible material may be wound between the first flange and the second flange; and a plurality of fasteners formed primarily of a wood-based or plastic material, each extending through a portion of the first flange and a corresponding one of the plurality of staves.

2. The reel of claim 1, further comprising at least a first metal fastener extending from the first flange to the second flange.

3. The reel of claim 1, wherein: the first flange further includes a second plate formed of the wood-based material; the first plate of the first flange is secured to the second plate of the first flange; and wherein the first annular channel extends axially at least partially through the second plate of the first flange.

4. The reel of claim 3, wherein at least one of the plurality of fasteners extends through the first plate of the first flange, the second plate of the first flange, and at least a portion of at least one of the plurality of staves.

5. The reel of claim 4, wherein: the at least one of the plurality of staves is inhibited from moving circumferentially within the first annular channel by the at least one of the plurality of fasteners; and at least one other of the plurality of staves is inhibited from moving circumferentially within the first annular channel by the at least one of the plurality of staves.

6. The reel of claim 1, wherein: the first flange further includes a further plate formed of the wood-based material; the first plate of the first flange is fixedly coupled to the further plate of the first flange; at least a portion of the further plate is disposed within an interior of a core formed by the plurality of staves; and at least one of the plurality of fasteners extends through a portion of the further plate of the first flange and one of the plurality of staves.

7. The reel of claim 6, wherein the at least one of the plurality of fasteners has a first end that is disposed at or underneath a radial outer surface of the at least one of the plurality of staves and a second end disposed within the further plate of the first flange.

8. The reel of claim 1, wherein each of the plurality of fasteners is a nail formed from wood.

9. A reel, comprising: a first flange including a first plate and a second plate, each of the first and second plates formed of a wood-based material, the first plate secured to the second plate at least in part by a plurality of fasteners formed of wood-based or plastic material, the second plate having a first annular channel; a second flange having a second annular channel; a plurality of staves, each stave extending from within the first annular channel to within the second annular channel, at least a first stave secured between the first flange and the second flange, wherein the plurality of staves collectively form a core surface around which flexible material may be wound between the first flange and the second flange.

10. The reel of claim 9, wherein each of the plurality of fasteners is a nail formed from a wood-based material.

11. The reel of claim 10, further comprising an adhesive disposed between at least a portion of at least a first nail of the plurality of fasteners and at least one of the group consisting of the first plate and the second plate.

12. The reel of claim 9, wherein: a first fastener of the plurality of fasteners includes a first shaft defining a first shaft axis; a second fastener of the plurality of fasteners includes a second shaft defining a second shaft axis; a core defined by the plurality of staves from a core axis, and wherein the first shaft axis and the second shaft axis are non-parallel to the core axis.

13. The reel of claim 12, wherein the first shaft axis is non-parallel to the second shaft axis.

14. The reel of claim 9, further comprising at least one further fastener formed of a wood-based or plastic material, the at least one further fastener extending through a portion of the first flange and a corresponding one of the plurality of staves.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1A is a front perspective view of a reel according to the disclosure;

[0013] FIG. 1B is an exploded perspective view of the reel of FIG. 1A;

[0014] FIG. 2 is a cross-sectional, fragmentary view of the reel of FIG. 1A showing sustainable fasteners driven into the layers of the flange;

[0015] FIG. 3 is a plan view of an exemplary sustainable fastener that may be used in the reel of FIG. 1.

[0016] FIG. 4 is a process diagram of a method for producing a flange of the reel of FIG. 1;

[0017] FIG. 5 shows a first modified version of the reel of FIG. 1; and

[0018] FIG. 6 shows a second modified version of the reel of FIG. 1.

DETAILED DESCRIPTION

[0019] For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains.

[0020] FIG. 1A depicts a front perspective view of a reel 100 having non-metal fasteners according to the disclosure. FIG. 1B shows an exploded view of the reel 100. The reel 100 includes a core 104 formed from a plurality of staves 108, and two opposing flanges 112. Each of the flanges 112 includes a first plate 116 and a second plate 120 that are connected to one another to form the respective flange 112. The plates 116, 120 may be formed of, for example, wood, wood-derived planking, plywood, or the like. In this embodiment the plates 116, 120 are connected in a way that facilitates recycling and sustainability.

[0021] As shown in FIGS. 1A and 1B, each of the flanges 112 is disk-shaped, and are coupled to the core 104 to form the completed reel 100. The flanges 112 can be coupled to the core 104 by any suitable means, including adhesive, fasteners, and the like. FIG. 1B shows an exploded view of an embodiment of the reel 100 wherein the flanges 112 are coupled via bolts 152, which are threaded through one of the flanges 112, extend through the interior of the core 104, and through the other flange 112. Nuts 154 then tightened onto the distal end of the bolts 152 to secure the connection of the flanges 112 with the core 104 disposed therebetween. As shown in FIG. 1B, in this embodiment, each of the staves 108 of the core 104 is received and seated in an annular channel 160 formed in the interior side of the flanges 112 (on the layer or plate 116).

[0022] With reference now to FIG. 2, the two plates 116, 120 of each flange 112 are connected to one another by, for example, an adhesive or an adhesive layer 132. The adhesive layer 132, however, requires time to cure. During the curing process, disturbing the plates 116, 120 could cause the two plates to become misaligned or disconnected from one another.

[0023] As seen in FIG. 2, the disclosed flange 112 includes a plurality of sustainable fasteners 136 coupling the plates 116, 120. In this embodiment, the fasteners are wooden nails driven through one of the plates 116 and into the other plate 120. In the illustrated embodiment, the sustainable nails 136 are formed of wood, for example beech wood. The reader should appreciate, however, that the sustainable nails 136 may be formed of a different recyclable material, for example paper, paperboard, plastic, fiberboard, composites, and the like. However, in this embodiment, the use of beech wood for the sustainable nails 136 allows for particularly efficient assembly.

[0024] In particular, each sustainable nail 136 is this embodiment may suitably be a can be a model Lignoloc wooden nail, available from Raimund Beck KG of Mauerkirchen, Austria. FIG. 3 shows a beechwood nail 300 that may be used as the sustainable nail 136. The beechwood nail 300 includes a shaft 302, a conical tip 304 at one end of the shaft, and a head 306 at the other end of the shaft 302, all formed form a single piece of beechwood. In this embodiment, the shaft 302 and head 306 form a continuous, elongate cylindrical body, and the conical tip 304 tapers conically from where it extends from the shaft to a point 308 at the distal end of the nail. In other embodiments, the head 306 may be wider than the shaft 304. In some embodiments, the conical tip 304 and/or lower part of the shaft 302 includes fluting, not shown, that helps improve the natural adhesive effect of lignin within the beechwood.

[0025] FIG. 2 shows a fragmentary cutaway view of the reel 100 where approximately half of the reel 100 is visible, and wherein the axial dimension is oriented horizontally. As shown in FIG. 2, the sustainable nails 136 produce a connection between the two plates 116, 120 that inhibits lateral movement of the plates 116, 120 relative to one another. As a result, the plates 116, 120 are disabled from becoming misaligned with one another while the adhesive layer 132 is curing. After the adhesive 132 is cured the sustainable nails 136 continue to reinforce the connection. In some embodiments or applications, the sustainable nails 136 alone can be enough to adequately secure the plates 116, 120 together.

[0026] Further, as seen in FIG. 2, the sustainable nails 136 are driven into the plates 116, 120 at an angle . In one embodiment, the angle may be between approximately 5 and approximately 25 relative to the direction normal to the inner surface of the inner plate 116. In another embodiment, the angle may be approximately 15 relative to the direction normal to the inner surface of the inner plate 116. The direction by which the angle is angled from the normal direction varies such that the sustainable nails 136 are oriented in different directions relative to the normal direction. In some embodiments, the angle may also vary for the individual sustainable nails 136. In the illustrated embodiment, the sustainable nails 136 are driven in pairs having oppositely oriented offset angles such that the sustainable nails 136 inhibit relative movement between the two plates 116, 120 in the direction along the normal direction.

[0027] As the sustainable nail 136 is driven into the plates 116, 120, the friction between the sustainable nail 136 and the plates 116, 120 produces heat, which causes the borders 140 between the sustainable nail 136 and the plates 116, 120 to fuse together similar to a weld. With the sustainable nail 136 formed of beechwood, the amount of lignin in the beechwood helps cause the fusion. As a result, the sustainable nail 136 not only resists lateral relative movement of the plates 116, 120, but also inhibits movement of the plates 116, 120 in the direction along the axis of the sustainable nail 136. This connection further supplements the connection produced by the angled arrangement of the nails discussed above.

[0028] FIG. 4 illustrates a process diagram of a method 200 for producing a reel flange such as the flange 112 of the reel 100. The method 200 begins with cutting the plates 116, 120 of the flange 112, or boards forming the plates 116, 120, to the desired sizes (block 204). The plates 116, 120 may be cut to a circular shape in this step, or it may be formed of boards with straight cuts that are arrangeable in the approximate rough size of the desired flange 112. Adhesive 132 is then applied to one side of each of the plates 116, 120 (block 208). The adhesive 132 may be curable liquid adhesive, an adhesive layer or sheet, or another desired adhesive.

[0029] The sides of the two plates 116, 120 having the adhesive 132 are then connected together (block 212). In one embodiment, the boards forming the plate 116 are aligned so as to be substantially perpendicular with the boards forming the plate 120.

[0030] The method 200 continues with driving sustainable nails 136 into the assembly of the two plates 116, 120 with the adhesive 132 (block 216). The sustainable nails 136 may be driven evenly in a circular pattern around the perimeter of the assembly or in two circular patterns with an offset angle that is opposite for the inner and outer circular patterns. In another embodiment, the sustainable nails 136 may be arranged irregularly in the two plates 116, 120. The adhesive 132 is then cured by, for example, allowing the two plates 116, 120 to rest for a predetermined period of time (block 220).

[0031] If the plates 116, 120 are not already in the desired shape, the double-layered flange blank may then be cut to the desired shape of the flange 112. Additionally, the flange 112 may be machined to incorporate the annular groove 160 to receive the staves 108, or other features desired in the flange 112. Two of the completed flanges 112 are then connected to a core 104, more specifically to opposite ends of the staves 108 of the core 104, by, for example, the bolts 152 and nuts 154. Alternatively, adhesives may be used to securely connect the flanges 112 and the core 104 and produce the completed reel 100.

[0032] The method 200 therefore securely retains the two plates 116, 120 together without the need to clamp the two plates 116, 120 together during the adhesive curing process. As such, the manufacturing cost and complexity of the flange 112 is reduced, thereby improving the efficiency of the reel production.

[0033] Further, the disclosed flange 112, and the reel 100 including the flange 112, are formed with only recyclable materials. For example, the flange layers 116, 120 and sustainable nails 136 may be formed of wood or wood-derived materials and adhesive. Since the flange 112 and reel 100 do not include metal fasteners, the flange 112 and reel 100 can therefore be easily recycled. The disclosed flange 112 and reel 100 are therefore more environmentally sustainable compared to conventional reels that are not recyclable without expensive metal removal. Even if plastic fasteners or nails are used in instead of the wood-based or cellulose based nails, the nails nevertheless can be easily ground at the useful end of life of the reel 100

[0034] It will be appreciated that the reel 100 can also include anti-rotation or anti-creep features that prevent or at least inhibit sliding movement of the staves 108 within annular channels 160. As mentioned above, even minor rotational movement of the core 104 between the flanges 112 with a loaded reel can damage the material that is wound on the core 104. The anti-rotation features of the reel can avoid the damage-causing movement. To this end, for example, one or more staves 108 can be set within the annular channel 160 with an adhesive, which locks that one or more staves 108 in place. Because there is a tight fit between all of the staves 108, the adhesively secured staves 108 also prevent the other staves 108 from moving. However, other anti-rotation features may also be used.

[0035] For example, FIG. 5 shows a cutaway fragmentary view of a modification of the reel 100 of FIG. 1 that uses sustainable fasteners 402 as an anti-rotation feature. In particular, as shown in FIG. 5, the reel 100 is the same as that of FIGS. 1 to 4 except that the reel 100 includes additional sustainable fasteners 402 that extend through at least a part of the flange 112 and at least part of the core 104. In this embodiment, the sustainable fasteners 402 are wooden nails driven through both plate 116 and plate 120, and through at least a portion of the core 104. In the illustrated embodiment, the sustainable fasteners 402 are formed of wood, for example beechwood, and may have structure of the sustainable nail 300 of FIG. 3. The reader should appreciate, however, that the sustainable nails 402 may be formed of a different recyclable material, for example paper, paperboard, plastic, fiberboard, composites, and the like. However, in this embodiment, the use of beechwood for the sustainable nails 402 allows for particularly efficient assembly.

[0036] The sustainable nails 402 are driven in at an angle measured from the plane of the surface of the flange 112, where is in the range between 5 to 90. Thus, in some embodiments, the sustainable nails 402 could be driven strictly in the axial direction (90) through the plates 116, 120 and into the core 104 (i.e. one or more of the staves 108). However, extending the sustainable nails 402 at axially inward angles (<90) also assists in resisting separation of the plates 116, 120.

[0037] The sustainable nails 402 preferably enter the core 104 within the annular channel 160, and are angled radially inward as discussed above. The sustainable nails 402 furthermore extend through the core 104 into the interior space within the core 104. In particular, to obtain maximum gripping, it is desirable that the shaft 406 of the sustainable nail 402 extend all the way through the material of the core 104 to maximize surface contact (and thus lignin bonding) between the shaft 406 of the nail 402 and the core 104. As a result, the conical tip 408 of the nail 402 extends beyond the inner surface and into the interior space of the core 104. If the nail 402 were instead angled radially outward (>90), then the tip 408 of the nail 402 would extend outward from the outer surface 104 of the core 104 on which the flexible cable or other media is wound, potentially causing damage.

[0038] It is noted that in an alternative embodiment, the reel 100 could omit the sustainable nails 136 that extend between the plates 116 and 120. Referring to FIGS. 1 and 5, the sustainable nails 402 that extend through the flange 112 and the core 104 may be used as the placeholders that assist in allowing the adhesive 132 to cure.

[0039] FIG. 6 shows a cutaway fragmentary view of another modification of the reel 100 of FIG. 1 that uses sustainable fasteners 452 as an anti-rotation feature in a different way. In the embodiment of FIG. 6, the sustainable fasteners 452 are inserted radially from the core 104 into an additional layer or plate 125 of the flange 112.

[0040] To this end, the reel 100 of FIG. 6 is identical to the reel 100, except that each flange 112 includes a third plate 125 that is disposed axially inward of the plate 116. The plate 125 is wood-based, and is sized and configured to fit within the interior of the core 104. The plate 125 may suitably be a disk plate having an outer annular edge that has a diameter roughly the same as the ID of the annular channel 160. The end portion of the core 104 thus surrounds the plate 125.

[0041] The sustainable fasteners 452, which may suitably take the form of the sustainable nail 300 of FIG. 3, are driven radially inward from the radially outward surface of the core 104, through the core 104, and into the outer annular edge of the plate 125. The sustainable fastener 452 can extend into the plate 125 such that most of the fastener 452 is within the plate 125 to provide solid structural retention. The reel 100 may otherwise have the same structure as the reel 100 of FIGS. 1 through 4.

[0042] It will be appreciated that the anti-rotation arrangements of FIGS. 5 and 6 may alternatively be used in conjunction with wood-based reels that do not include both of the plates 116, 120, but instead have single plate or single layer flanges. For example, the flange 112 of FIG. 6 may be made of a single piece of lumber machined to have an additional structure corresponding to the plate 125.

[0043] It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the foregoing disclosure.