AU2320001A - Collapsible reel assembly - Google Patents

Description

-1-

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Viscount Plastics (NSW) Ltd Actual Inventors: Philip Duncan Loader and Martin Svaabeck and Kevin Michael Hannon Address for Service: BALDWIN SHELSTON WATERS 60 MARGARET STREET SYDNEY NSW 2000 Invention Title: 'COLLAPSIBLE REEL ASSEMBLY' Details of Associated Provisional Application No. PQ5828 dated 24 Feb 2000 The following statement is a full description of this invention, including the best method of performing it known to me/us:- File: 30977AUP00 V.i -2- Field of the Invention The present invention relates to reels and in particular to a collapsible reel assembly.

Background of the Invention Reels are known as a means of conveniently storing and dispensing wire, rope, cord, cable, foil, tape and other flexible elongate materials. Early reel designs were typically formed as a one piece unitary structure including a spool around which the material is wound, and radially extending end flanges to retain and protect the material on the spool. The size and shape of the spool, and particularly the flanges, mean that when not in use, such reels are bulky and spatially inefficient for storage and transportation.

In an attempt to reduce the overall size, it is also known to provide reels in three parts consisting of a generally cylindrical spool and a pair of generally planar detachable end flanges. These reels were adapted to be assembled before use, which typically involved a relatively time consuming procedure, often requiring special tools. However, even these collapsible reels continued to include a bulky spool.

In an attempt to address this problem, reels have more recently been formed with spools which are themselves collapsible into a flat or substantially flat configuration Otto once detached from the end flanges. In one particular known form, the components of the reel are releasably secured together by means of axially extending spigots formed on the spool and corresponding key hole slots formed in the flanges. Each spigot typically includes a shank and a relatively broad head such that upon insertion of the spigots on each end of the spool into the corresponding keyhole slots in the respective flange, and -3upon subsequent relative rotation between the spool and the flange, these components are releasably secured together.

In order to prevent reverse rotation, and the spool consequently detaching inadvertently from the flange, locking clips are provided on the inner face of each flange.

These clips are typically recessed to remain flush with the exposed surfaces of the spool and flange. In practice, however, it is possible and indeed commonplace, for these clips to disengage unintentionally during the reel winding process and as a consequence, the spool and flange can come apart. If this occurs, it is impossible due to the location of the clips beneath the material wound on to the spool, to re-engage the clips without first unwinding the entire reel. Similarly, if a flange is damaged when the reel has material wound on it, the damaged flange cannot be replaced without first accessing the locking ooo.

clips, which again requires the entire reel to be unwound. In either case, this is a time S•consuming and expensive process with potential to cause significant downtime in a o. production or packaging line.

Another deficiency of the prior art arises from the fact that the spigots not only :..oo 'o..obear a tensile load in attaching the spool to the flanges, but also a shear load as a result of torsion between the flanges and spool. If the shear stress becomes excessive, as can 0 occur particularly during winding and subsequent handling of the reel, the spigots can i' become permanently deformed or fail altogether.

In addition, the spools themselves are prone to deform into an "hour-glass" shape, due to the compressive hoops stresses which typically arise as material is wound under tension onto the reel. This particular problem is exacerbated if the reel is made from plastics material and exposed to heat during the winding process, as often occurs.

-4- A further problem relates to such spools in their disassembled state. Although the individual sections of spool are generally flat and therefore less bulky, they incorporate no integral means for stacking and therefore usually require some form of external packaging for storage or transportation.

It is an object of the present invention to overcome or substantially ameliorate one or more of the disadvantages of the prior art, or at least to provide a useful alternative.

Disclosure of the Invention Accordingly, the invention provides a reel assembly including: a spool having at least one first locating formation and a plurality of first locking elements at each end; a pair of end flanges adapted respectively for releasable connection to the ends of the spool, each flange including a complementary second locating formation adapted .ooo releasably to engage the first locating formation on the spool to prevent relative rotation S. between the flange and the spool, and a plurality of apertures adapted respectively to 15 align with the first locking elements on the spool; ooooi a pair of intermediate plates adapted respectively for releasable connection to said flanges, each intermediate plate having a plurality of complementary second locking oooe o oe"elements adapted axially to align with the respective apertures on the corresponding flange and the respective first locking elements on the spool, such that upon relative 0 20 rotation of the spool and the intermediate plates, the respective first and second locking elements are captively retained in interlocking engagement, with the flanges sandwiched between the respective intermediate plates and the spool, thereby releasably securing the flanges to the spool; and a pair of locking plates releasably engageable to prevent relative reverse rotation of the respective intermediate plates with respect to the spool and hence withdrawal of the flanges from the spool.

Preferably, there are twelve first locating elements on each end of the spool and twelve corresponding second locating elements on each flange. Each flange preferably has an inner face having an annular recess for respectively locating each end of the spool, which is generally annular in cross sectional profile. Preferably the first locating elements are uniformly spaced around each end of the spool and extend radially outwardly therefrom. Also preferably, the corresponding second locating elements extend radially inwardly from the outer peripheral surface of the annular recess of each flange.

In a preferred embodiment, there are twelve uniformly distributed first locking oooo elements on each end of the spool. Each first locking element preferably includes a mushroom formation having a shank and a relatively broad head having a generally "D" 15 shaped cross sectional profile. There are twelve correspondingly spaced apertures on ooooo each of the flanges and a further twelve keyhole slots on each of the intermediate plates, all of which are appropriately shaped and spaced to receive the shaped heads of the '"first locking elements. Further, each keyhole slot is preferably shaped to allow insertion of the shaped head of the respective first locking element and to allow relative 20 rotation of the intermediate plate and the spool, so that the shanks slide along the narrow sections of the keyhole slots to captively retain the intermediate plate under the heads of the mushroom formations.

In an alternative embodiment, the mushroom formations are located on the intermediate plates, and the key hole slots are formed in the ends of the spool.

-6- The reel preferably further includes attachment means to provide for simultaneous releasable attachment of the locking plate to the flange and intermediate plate.

Preferably, the attachment means takes the form of two pairs of sockets on the locking plate adapted for releasable snap locking engagement with a corresponding pair of spigots on the respective flange and a further pair of corresponding spigots on the respective intermediate plate, thereby to prevent relative rotation therebetween.

In a further preferment the spool is formed from two sections, each having six parallel segments. Preferably these segments are hingedly interconnected about substantially parallel axes by means of flexible wall sections extending between adjacent longitudinal edges.

Preferably each segment includes longitudinal and transverse ribbing to enhance oo *oo rigidity. Preferably each section includes an alignment formation on its upper surface, disposed to engage a corresponding alignment formation on the lower surface of a like section to facilitate stable stacking of multiple sections. Preferably the flanges also include complementary alignment formations to facilitate vertical stacking.

.ooooi Brief Description of the Drawings A preferred embodiment of the invention will now be described, by way of o• example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a collapsible reel assembly according to the 20 invention; Figure 2 is an exploded perspective view of the collapsible reel assembly of Figure 1; Figure 3A is a perspective view of one of the end flanges showing the inside surface and annular recess; -7- Figure 3B is a reverse perspective view of a flange showing the exterior surface; Figure 4A is a perspective view of a half-spool section in the operative curved configuration displaying the outside surface; Figure 4B is a reverse perspective view of the spool section of Figure 4A; Figure 5A is a perspective view of a spool section in the flattened configuration showing longitudinal and transverse internal ribbing.

Figure 5B is a reverse perspective view of the spool section of Figure 5A, showing the outside surface as in Figure 4A; Figure 6A is a perspective view of an intermediate plate showing the inwardly facing surface; Figure 6B is a reverse perspective view of the intermediate plate of Figure 6A oooo showing the outwardly facing surface; Figure 7A is a perspective view of a locking plate showing the outwardly facing surface; and Figure 7B is a reverse perspective view of the locking plate of Figure 7A showing the inwardly facing surface.

Preferred Embodiments of the Invention Referring to the drawings, the invention provides a collapsible reel assembly 1 including a spool 2, and a pair of end flanges 3 adapted respectively for releasable connection to opposite ends of the spool. As best seen in Figure 2, a series of twelve first locating formations 4 extend radially outwardly, and series of twelve first locking elements 5 extend generally axially, from each end of the spool. As seen in Figure 4A, each adjacent pair of first locating elements 4 defines an intermediate generally Vshaped notch 6. Each of the first locking elements 5 comprises a mushroom formation, -8having a shank 7 and a relatively broad head 8. The head has a generally shaped cross sectional profile.

As best seen in Figures 2, 4 and 5, the spool is formed in two half cylindrical sections 9, each section comprising six elongate axially extending parallel segments The segments include longitudinal and transverse internal ribbing 11 to enhance rigidity.

The segments of each spool section are hingedly interconnected about substantially parallel hinge axes, by means of flexible walls 12 extending between each adjacent pair of longitudinal edges. Each section has alignment formations (not shown) on the inner surface and complementary alignment formations (also not shown) on the outer surface to facilitate stable vertical stacking of multiple sections 9.

The two half cylindrical sections 9 are joined together by mutually interengagable *o releasable locking formations extending along their mating edges. In this embodiment, the formations are a tongue flange 13 which engages a corresponding groove 14 on the other section.

Each flange 3 includes an inner face having an annular recess 15 to receive and locate the corresponding end of the spool. The annular recess 15 also includes an outer peripheral surface 16 having twelve complementary second locating formations 17 extending radially inwardly. These second locating formations 17 take the form of generally V-shaped projections adapted releasably to engage the corresponding V-shaped 20 notches formed by the twelve first locating formations 4 on the spool 2, to prevent relative rotation between the spool and the respective flanges. Each flange 3 further includes twelve apertures 20, each of which takes the form of a shaped hole. This allows the respective complementary shape heads 8 of the first locking elements on the spool 2 to be inserted axially therethrough.

-9- A pair of intermediate end plates 21 are adapted for releasable connection to the respective flanges 3. Each intermediate plate 21 has twelve second locking elements in the form of keyhole slots 23. These slots are adapted to axially receive the respective first locking elements, in the form of mushroom formations 4 on the spool 2, the heads 8 of which are first inserted through the apertures 20 on the respective flange 3. Then, upon relative rotation between the intermediate plate 21 and the spool 2, the narrow sections of the keyhole slots 23 captively engage the mushroom formations 4, with the respective flange 3 thereby sandwiched firmly between the intermediate plate 21 and the spool 2.

Figure 6B shows keyhole slots 23 including an enlarged section 24 at one end to allow insertion of the shaped head 8 of the mushroom formation 4 and a reduced section 25 at the other end to slip under the shaped head and provide the locking engagement. While the first locking elements on the spool are most conveniently shaped as mushroom formations and the corresponding keyhole slots are disposed on the intermediate plate, it will be appreciated that their locations may be reversed. That is, the first locking elements on the spool may be embodied as keyhole slots and the second locking elements on the intermediate plate may be embodied as mushroom formations.

It will also be appreciated that these locking formations made be embodied in other •forms.

20 A pair of locking plates 30 are adapted for releasable attachment to prevent reverse relative rotation of the respective intermediate plates 21 with respect to the spool 2.

Each locking plate 30 includes two pairs of sockets 31 and 32. The sockets 31 are adapted for releasable engagement with a corresponding pair of spigots 33 on the respective intermediate plate 21, while the sockets 32 are adapted for simultaneous engagement with a complementary pair of spigots 34 on the corresponding flange 3.

Each of the spigots includes a circumferential rim adapted for snap locking engagement with a complementary circumferential groove formed on the internal surface of the corresponding socket.

Each locking plate 30 and intermediate plate 21 further includes a respective pair of mutually inter-engageable oppositely directed abutment formations 35. These formations are disposed to assist in preventing relative rotation of the intermediate plate 21 with respect to the flange 3.

Turning now to describe briefly the procedure for assembling the spool, both of the spool sections are initially rolled into two semi-cylindrical sections 9 as shown in Figures 2, 4A and 4B. These sections 9 are then joined together by their respective tongues and grooves 13 and 14 to form the cylindrical spool 2 as shown in Figure 1. The oooa radial V-shaped notches 6 on the spool 2 are then aligned with the corresponding Vshaped projections 17 on the first flange and the spool is inserted into the annular recess oo on the flange. With the spool fully inserted in the flange, the shaped heads 8 of the 555555 ***mushroom formations 5 extend through the apertures to protrude axially from the outer face of the flange. The other end of the spool is then inserted into the annular recess o•o• on the second flange by aligning the respective locating formations 6 and 17 so that, the mushroom formations 5 on the spool pass through the second flange. This S. 20 establishes the basic shape of the reel.

In turn, each intermediate plate 21 is then attached to the respective end of the reel outside the flanges 3, by aligning the keyhole slots 23 on the intermediate plate with the mushroom formations 5 on the spool. Care must be taken to position the spigots 33 on the intermediate plates, adjacent the spigots 34 on the corresponding flanges, so that -11 when each intermediate plate is rotated, the spigots will line up. With each intermediate plate located in this way, the mushroom formations 5 pass through the wider sections of the key hole slots 23, so that the heads 8 clear the plate. This allows the plate to be rotated with respect to the spool and flanges. During this process, the shanks 7 of the mushroom formations slide into the narrow sections 25 of the respective keyhole slots so that the intermediate plate is secured underneath the shaped heads.

Finally, the socket pairs 31 and 32 on each locking plate 30 are aligned with the corresponding pairs of spigots 33 and 34 on the respective flange and intermediate plate.

The locking plate is then pressed into position and secured by snap locking engagement, to prevent reverse relative rotation between the intermediate plates and the spool, and thereby to prevent disengagement of the flanges. This completes the assembly of the reel and disassembly is essentially the reverse of this procedure.

The invention at least in its preferred embodiments thus provides a collapsible reel S" which can be assembled and disassembled quickly and easily without the use of special tools. The spool itself is strengthened to enhance rigidity and resist "hour-glass" .ooooi deformation during winding. The ends of the spool are also fully supported by an annular recess in each flange to further enhance rigidity. Additionally, the locking mechanism is essentially located on the outside of the reel so that a flange may be o replaced if damaged, without unwinding the reel. This configuration also enables access .i 20 to the locking mechanism should it become disengaged while the reel is being wound although the locking plates serve to minimise the possibility of inadvertent disengagement. Furthermore, the axial flange locking mechanism is distinct from the radial locating mechanism. Consequently, the torsional forces of winding between the flanges and spool are isolated and borne by a different set of elements to those bearing -12the tensile loads which retain the flanges on the spool. In particular, the locking elements are substantially isolated from shear stresses. This results in a stronger, more rigid reel, which is less prone to deformation or failure due to mishandling or under heavy load conditions. In all these respects, the invention represents practical and commercially significant improvement over the prior art.

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in other forms.

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Claims (10)

13- THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:- 1. A collapsible reel assembly including: a spool having at least one first locating formation and a plurality of first locking elements at each end; a pair of end flanges adapted respectively for releasable connection to the ends of the spool, each flange including a complementary second locating formation adapted releasably to engage the first locating formation on the spool to prevent relative rotation between the flange and the spool, and a plurality of apertures adapted respectively to align with the first locking elements on the spool; a pair of intermediate plates adapted respectively for releasable connection to said flanges, each intermediate plate having a plurality of complementary second locking elements adapted axially to align with the respective apertures on the corresponding S••flange and the respective first locking elements on the spool, such that upon relative .i 15 rotation of the spool and the intermediate plates, the respective first and second locking elements are captively retained in interlocking engagement, with the flanges sandwiched between the respective intermediate plates and the spool, thereby releasably securing the flanges to the spool; and a pair of locking plates releasably engageable to prevent relative reverse rotation of 20 the respective intermediate plates with respect to the spool and hence withdrawal of the flanges from the spool. 2. A collapsible reel assembly according to claim 1 wherein each of the first locking elements includes a mushroom formation having a shank and a relatively broad head, and wherein each of the second locking elements includes a complementary key hole -14- slot, such that upon relative rotation of the spool and intermediate plates, the mushroom formations at each end of the spool are captively retained by the corresponding key hole slots in the respective intermediate plates, thereby releasably securing the flanges to the spool. 3. A collapsible reel assembly according to claim 2 wherein the head of each mushroom formation has a generally shaped cross-sectional profile and wherein the apertures on the flange are correspondingly shaped to receive the respective heads. 4. A collapsible reel assembly according to claim 1 wherein each of the second locking elements includes a mushroom formation having a shank and a relatively broad 1o head, and wherein each of the first locking elements includes a complementary key hole slot, such that upon relative rotation the mushroom formations on the intermediate plates are captively retained by the corresponding key hole slots in the respective ends of the o. spool, thereby releasably securing the flanges to the spool. A collapsible reel assembly according to claim 4 wherein the head of each mushroom formation has a generally shaped cross-sectional profile and wherein the *apertures on the flange are of an elongate shape suitable to receive the respective "D" shaped heads and allow relative rotation between the respective intermediate plates and flanges. 6. A collapsible reel assembly according to any one of the preceding claims wherein .i 20 each of said flanges includes an inner face having an annular recess to receive and locate the corresponding end of said spool. 7. A collapsible reel assembly according to any one of the preceding claims, including a plurality of said first locating formations on each end of the spool for engagement with a corresponding plurality of the second complementary locating formations on the flange. 8. A collapsible reel assembly according to any one of the preceding claims wherein the first locating formations are uniformly disposed around the respective ends of the spool and the complementary second locating formations on each flange are correspondingly disposed. 9. A collapsible reel assembly according to any one of claims 6 to 8 when dependent upon any one of claims 1 to 3, wherein the first locating formations extend radially outwardly from the respective ends of the spool and the corresponding second locating formations on each flange extend radially inwardly from the outer peripheral surface of the annular recess. 10. A collapsible reel assembly according to claim 9 wherein the first locking elements oo are uniformly disposed around the respective ends of the spool to extend axially in S-directions parallel to a central axis of the spool, the apertures are correspondingly disposed around the annular recess of each flange, and the second locking elements are correspondingly disposed about the intermediate plate. 11. A collapsible reel assembly according to any one of the preceding claims, including twelve of the first locking elements on each end of the spool, twelve of the apertures on each flange, and twelve of the second locking elements on each 20 intermediate plate. 12. A collapsible reel assembly according to any one of the preceding claims, including twelve of the first locating formations on each end of the spool, and twelve of the second complementary locating formations on each flange. -16- 13. A collapsible reel assembly according to any one of the preceding claims wherein each of said locking plates includes attachment means for releasable simultaneous attachment to the respective intermediate plate and the respective flange, thereby to prevent relative rotation therebetween.

14. A collapsible reel assembly according to claim 13 wherein the attachment means on each of the locking plates include a first pair of sockets adapted for engagement with a corresponding pair of spigots on the respective intermediate plate and a second pair of sockets adapted for engagement with a corresponding second pair of spigots on the respective flange.

15. A collapsible reel assembly according to claim 14 wherein each of the spigots includes a circumferential rim adapted for releasable snap locking engagement with a .09. 0complementary circumferential groove formed on an internal surface of the 9@S* .•corresponding socket. a.

16. A collapsible reel assembly according to any one of the preceding claims wherein 99 94 each of said intermediate plates and the corresponding locking plate include respective mutually inter-engageable oppositely directed abutment formations disposed to prevent relative rotation of the intermediate plate with respect to the flange. go

17. A collapsible reel assembly according to any one of the preceding claims wherein the spool is formed from a plurality of elongate axially extending parallel segments.

18. A collapsible reel assembly according to claim 17 wherein the segments are hingedly interconnected about substantially parallel hinge axis.

19. A collapsible reel assembly according to claims 17 or 18 wherein adjacent segments are hingedly interconnected by means of a flexible wall extending between adjacent longitudinal edges. -17- A collapsible reel assembly according to any one of claims 17 to 19 wherein the spool is formed in two sections, each comprising a series of six of the interconnected segments.

21. A collapsible reel assembly according to claim 20 wherein each section includes an alignment formation on the inner surface and a complementary alignment formation on the outer surface, to facilitate stable stacking of multiple sections.

23. A collapsible reel assembly according to any one of claims 17 to 21 wherein the segments include longitudinal and transverse ribbing to enhance rigidity.

24. A collapsible reel assembly substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings. DATED this 23rd Day of February, 2001 VISCOUNT PLASTICS (NSW) LTD Attomey: STUART M. SNUTH Fellow Institute of Patent Attorneys of Australia of BALDwiN SBELSTON WATERS