AU2001275602B2 - Collapsible reel assembly - Google Patents

Description

WO 02/08107 PCT/AU01/00904 -1- TITLE: COLLAPSIBLE REEL ASSEMBLY Field of the Invention The present invention relates to reels and in particular to a 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 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 are adapted to be assembled before use, which typically involves a relatively time consuming procedure, often requiring special tools. However, even these reels include a bulky cylindrical spool.

In an attempt to address this problem, reels have more recently been fabricated with spools which are themselves formed from a flat or substantially flat original configuration. 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 upon 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 WO 02/08107 PCT/AU01/00904 -2inner face of each flange. These clips are typically recessed to remain flush with the exposed surfaces of the spool and flange. While this design allows for the reel to be conveniently assembled and disassembled, it requires relatively complex component parts and the assembly procedure is cumbersome, all of which add to the manufacturing cost. Moreover, it has been found in practice that many users of the reels do not actually require the facility which allows the reels to be disassembled after use, which renders the additional cost for this functionality unjustifiable.

Further, in practice it is possible and indeed commonplace, for the locking clips to disengage unintentionally during the reel winding process, or subsequently during handling or transportation, and as a consequence, the spool and flanges can come apart.

If this occurs, due to the location of the clips beneath the material wound onto the spool, it is impossible to re-engage the clips without first unwinding the entire reel.

Another deficiency of the prior art arises from the fact that the spigots bear not only 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 resultant shear stress becomes excessive, as can occur particularly during winding and subsequent handling of the reel, the spigots can become pennanently deformed or fail altogether.

In addition, the spools themselves are prone to deform into an "hour-glass" shape, due to the compressive hoop stresses which typically arise as material is progressively 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 is often the case.

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 WO 02/08107 PCT/AU01/00904 -3no integral means for stacking and therefore usually require some form of external packaging for storage and 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 a plurality of first engagement formations at each end; a pair of end flanges each including a plurality of complementary second engagement formations, the respective first and second formations being disposed to permit axial engagement of each flange with a corresponding end of the spool in a release position, and the first and second engagement formations including mutually opposing engagement surfaces positioned circumferentially in mating pairs such that relative rotation in a predetermined forward direction from the release position to a locked position prevents axial disengagement of the spool and the flange; and a one way locking catch associated with each end flange and adapted for sliding engagement with a corresponding deflection surface, the locking catch being adapted to be resiliently deformed in response to said axial engagement or said relative rotation, the deflection surface defining a shoulder permitting resilient relaxation of the locking catch in the locked position, and the catch including a locking surface engageable with the shoulder in the locked position to resist reverse relative rotation, and thereby prevent inadvertent axial disengagement, of the respective flange from the spool.

Preferably, the reel further includes stop means in the form of mutually engagable oppositely directed ends stops disposed on the flanges and the spool respectively to prevent rotation of each flange relative to the spool beyond the locked WO 02/08107 PCT/AU01/00904 -4position. Preferably, the end stops are integral with the respective first and second engagement formations of each mating pair.

Preferably, a plurality of the locking catches and corresponding deflection surfaces are also integral with the respective engagement formations. More preferably, the deflection surfaces are integral with the first engagement formations and the locking catches are integral with the second engagement formations. However, in an alternative embodiment, the deflection surfaces are integral with the second engagement formations and the locking catches are integral with the first engagement formations.

Preferably, the first and second engagement formations comprise respective first and second locking lugs disposed in complementary circumferential arrays.

Preferably the engagement surfaces on both the first and second engagement formations are correspondingly ramped and disposed for sliding surface to surface contact. In this way, the flanges and spool are drawn together in a wedging action as the ramped surfaces progressively interengage, in response to the relative rotation toward the locked position. However, in alternative embodiments, only one of the first or second engagement surfaces of each mating pair is ramped. It will also be appreciated that neither surface need be ramped.

Preferably the engagement fornations, locking catches and deflection surfaces are uniformly spaced around each end of the spool and correspondingly located on each flange. Preferably, there are six of the first engagement formations and six of the associated deflection surfaces on each end of the spool, and six of the second engagement formations and six of the associated locking catches on each flange.

Preferably, the first engagement formations are directed radially inwardly from each end of the spool. However, in alternative embodiments, the first engagement formations may be directed radially outwardly.

WO 02/08107 PCT/AU01/00904 Preferably, each of the flanges includes an inner face having an annular recess to receive and radially locate the corresponding end of the spool.

Preferably, the spool is formed from a plurality of elongate axially extending parallel segments hingedly interconnected about substantially parallel hinge axes.

Preferably, the segments are hingedly interconnected by means of a thin flexible wall section extending between adjacent longitudinal edges.

Preferably, the spool is formed in two sections each comprising a series of six of the interconnected segments. Each section preferably includes an alignment formation on the inner surface and a complementary alignment formation on the outer surface to facilitate stable stacking of multiple sections. Preferably also, the segments include longitudinal and transverse ribbing to enhance rigidity.

Brief Description of the Drawings A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a reel assembly according to the invention; Figure 2 is an exploded perspective view of the reel assembly of Figure 1; Figures 3A to 3F are enlarged detailed sectional views showing in sequence the configurations of the engagement formations and locking catches as a flange is progressively engaged with and locked onto the spool; Figure 4 is a perspective view of a reel assembly according to an alternative embodiment of the invention; Figure 5 is an exploded perspective view of the reel assembly of Figure 4; and Figure 6 is a plan view of the outer face of one of the end flanges of the reel assembly shown in Figure 4.

WO 02/08107 PCT/AU01/00904 -6- Preferred Embodiments of the Invention Referring to the drawings, the invention provides a reel assembly 10 including a spool 20 and a pair of end flanges 30. The spool includes an array of six first engagement formations 40 uniformly spaced around each end. Each array of first engagement formations is adapted to mate with a corresponding array of six second engagement formations 50 on a respective flange 30. Each flange includes an inner face 31 having an annular recess 32 to' receive and radially locate the corresponding spool end. The annular recess 32 includes an inner peripheral surface 33 on which the second engagement formations are located.

Both sets of engagement formations take the form of circumferentially extending lugs. The first engagement formations 40 on the spool are directed radially inwardly toward the longitudinal axis of the spool, while the second complementary engagement formations 50 on each flange are directed radially outwardly.

In alternative embodiments, the first engagement formations may be directed radially outwardly from each end of the spool with the second engagement formations directed radially inwardly. In still further embodiments, any combination of first engagement formations directed radially inwardly and outwardly may be used with the second engagement formations correspondingly located.

As best seen in Figure 3A, each first engagement formation 40 includes a ramped engagement surface 41, an end stop 42 and a deflection surface 43 defining a locking shoulder 44. Each second engagement formnation 50 includes a correspondingly ramped engagement surface 51, an end stop 52 and a one way resilient locking catch 53 defining a locking surface 54.

As best seen in Figure 2, the spool 20 is formed in two half cylindrical sections 21, each section comprising six elongate axially extending parallel segments 22. These WO 02/08107 PCT/AU01/00904 -7segments include longitudinal and transverse internal ribbing 23 to enhance rigidity.

The segments of each spool section are hingedly interconnected about substantially parallel hinge axes, by means of flexible wall sections 24 extending between each adjacent pair of longitudinal edges. Each section has alignment formations 29 on the inner surface and complementary alignment formations 29 on the outer surface to facilitate stable vertical stacking of multiple sections.

The two half cylindrical sections are joined together by mutually interengageable formations extending along their mating edges. These formations take the form. of a tongue flange 25 which engages a corresponding groove 26 on the other section.

It will be appreciated that while the engagement formations include the abutment means and the locking catch and shoulder as integral parts, alternative embodiments of the invention may provide them as separate and distinct components.

Turning now to describe briefly the procedure for assembling the reel, both of the spool sections 21 are initially rolled into two half cylindrical sections as shown in Figure 2. These half cylindrical sections are then joined together by their respective tongues and grooves 25 and 26 to form the composite cylindrical spool as shown in Figure 1.

Figures 3A to 3F show step by step views of the inter-relationship between the first and second engagement formations as each flange is connected to the spool. Thus, the first flange is initially positioned adjacent one end of the reel with the first and second engagement formations 40 and 50 mutually offset, as shown in Figure 3A. In this way, the engagement formations 40 on the spool 20 are aligned with the spaces between the second engagement formations 50 on the flange. The spool is then inserted axially into the annual recess 32 on the flange, as indicated by arrows A in Figure 3B, until the respective sets of first and second engagement formations move past and clear one another. This position is referred to as the release position and is best seen in Figure 3C.

WO 02/08107 PCT/AU01/00904 -8- From this position, the spool and flange are rotated relative to one another in a forward direction as indicated by arrows B in Figure 3D and 3E, from the release position toward a locked position which will be described in more detail below. During this movement, the ramped engagement surfaces 41 and 51 progressively overlap and engage in sliding surface to surface contact. In this way, the forward relative rotation produces a wedging action which progressively draws the flange and spool axially together, as indicated by arrows C in Figure 3E.

Simultaneously, as the flange is rotated, each deflection surface 43 on the spool slidingly contacts the corresponding locking catch 53 on the flange. This contact, in conjunction with the interaction between the ramped engagement surfaces, 41 and 51, provides an axial deflection force on the catch 53. This force resiliently deforms the catch in an upward direction (when viewing the drawings) as shown in Figures 3D and 3E, by arrow D.

In response to further rotation, the flange and spool reach the locked position, as shown in Figure 3F. In this position, the locking catch 53 clears the deflection surface 43 and resiliently returns to its relaxed position in a snap-locking movement, shown by arrow E. Once in this position, the locking surface 54 on the catch abuts the locking shoulder 44 on the first engagement formation, thereby preventing reverse rotation of the spool with respect to the flange. Additionally, the flange is prevented from relative rotation beyond the locked position, by means of the end stops, 42 and 52, which are now mutually opposed in abutting engagement (see Figure 3F).

In summary, in the locked position, further forward rotation of the flange with respect to the spool is prevented by the opposing end stops, reverse rotation is prevented by the catches abutting the respective locking shoulders, while axial disengagement is prevented by the mutually opposed engagement surfaces of the respective mating pairs WO 02/08107 PCT/AU01/00904 -9of first and second engagement formations. The other flange is attached to the opposite end of the spool in the same manner, to complete the assembly of the reel.

Disassembly of the reel is a more complicated procedure requiring each catch on each flange to be simultaneously resiliently deformed sufficiently to clear the locking shoulders of the respective first engagement formations. This allows reverse relative rotation into the release position and then subsequent axial disengagement of the flange from the spool. Thus, disassembly may be made easier by the use of a special tool designed to engage all of the locking catches simultaneously.

An alternative embodiment of the reel is shown in Figures 4, 5 and 6, wherein like features are denoted by corresponding reference numerals. In this case, there are six outwardly facing first engagement formations 47 and six inwardly facing first engagement formations 48 at each end of the spool. The inwardly and outwardly facing formations are alternately positioned around each end of the spool to distribute forces as evenly as possible. The complementary second locking formations are appropriately positioned on each flange.

In this embodiment, the tongue and groove formations are replaced by tabs and corresponding apertures. As shown in Figure 4 each mating edge has a number of tabs 27 and corresponding apertures 28. The tabs engage the apertures to locate and releasably attach the spool sections together.

Further, the flanges also include a number of additional features designed to aid in loading (winding) the reel, and transporting the reel in both assembled and disassembled states. As seen in Figure 6, the flanges each include two oppositely directed tapered apertures 61 positioned adjacent but outwardly of the locking formations. One longitudinal side of each aperture includes serrations 62 for securing the end of a cable, prior to winding. The serrations and tapered shape of the apertures 61 enable a variety of WO 02/08107 PCT/AU01/00904 sizes of cable to be secured. Moreover, by having two such apertures oppositely directed, it is possible to commence winding the reel in either direction.

In addition, each flange includes a smaller aperture 63 also adjacent the locking formation, for securing the end of cable too small for the tapered apertures, such as mini or optic cable. Each flange also includes a series of apertures 64 at its periphery to enable the free end of the cable to be tied off when fully wound.

Each flange further includes a radial array of alignment formations in the form of posts 65 protruding from the outer surface, and a corresponding array of complementary alignment formations in the form of apertures 66 on the inner surface. The posts of one flange are adapted for interlocking engagement with the alignment apertures of an adjacent like flange thereby to facilitate stable stacking of the disassembled flanges for transportation. The posts on the outer surface are also positioned to interact with the ribbing 67 on an adjacent like flange. This allows for outer face to outer face stacking of the assembled reels.

Each flange also includes an additional aperture 68 adjacent but inwardly of the locking formations for storage of excess cable ends within the internal area of the spool.

The invention provides a reel assembly, the components of which can be assembled quickly and easily into snap-locking engagement without the use of special tools. The reel includes a minimal number of component parts and allows no movement between them in the assembled state. This has the benefits of a cheaper and stronger, more durable reel. Further, the assembly process is simplified and thus less time consuming.

Furthermore, due to the one-way snap locking engagement mechanism, and the requirement for a special tool for disassembly, the possibility of inadvertent disassembly is effectively eliminated. In addition, the broad cross section of the catches provides a WO 02/08107 PCT/AU01/00904 -11higher resistance to sheer loading and consequently the possibility of damage due to torsional forces during winding is greatly reduced. Further, the annular insert provides support to the spool against bending loads. 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 many other forms.

Claims (29)

1. A reel assembly including: a spool having a plurality of first engagement formations at each end; a pair of end flanges each including a plurality of complementary second engagement formations, the respective first and second formations being disposed to permit axial engagement of each flange with a corresponding end of the spool in a release position, the first and second engagement formations including mutually opposing engagement surfaces oriented circumferentially in mating pairs such that relative rotation in a predetermined forward direction from the release position to a locked position prevents axial disengagement of the spool and the flange; and a one way locking catch adapted for sliding engagement with a deflection surface, the locking catch being adapted to be resiliently deformed in response to said axial engagement or said relative rotation, the deflection surface defining a shoulder permitting resilient relaxation of the locking catch in the locked position, and the catch including a locking surface engageable with the shoulder in the locked position to resist reverse relative rotation and thereby prevent inadvertent axial disengagement of the flange from the spool.

2. A reel assembly according to claim 1 further including abutment means disposed to prevent rotation of the flanges relative to the spool beyond the respective locked positions.

3. A reel assembly according to claim 2 wherein the abutment means includes mutually engagable oppositely directed end stops disposed on the flanges and spool respectively.

4. A reel assembly according to claim 3 wherein the stop means are integral with the first and second engagement formations.

WO 02/08107 PCT/AU01/00904 -17- AMENDED CLAIMS [received by the International Bureau on 30 October 2001 (30.10.01) claim 5 amended; other claims unchanged] A reel assembly according to any one of the preceding claims wherein the locking catches and surfaces are integral with the engagement formations.

6. A reel assembly according to claim 5 wherein the deflection surfaces are integral with the first engagement formations and the locking catches are integral with the second engagement formations.

7. A reel assembly according to any one of the preceding claims wherein the deflection surfaces are integral with the second engagement formations and the locking catches are integral with the first engagement formations.

8. A reel assembly according to any one of the preceding claims wherein the first engagement formations are an array of circumferentially extending first locking lugs.

9. A reel assembly according to any one of the preceding claims wherein the second engagement formations are an array of circumferentially extending second locking lugs.

A reel assembly according to any one of the preceding claims wherein at least one of the engagement surfaces on a corresponding one of the first engagement formations is ramped so that the flanges and spool are drawn together in response to the relative rotation toward the locked position.

11. A reel assembly according to any one of claims 1 to 9 wherein each engagement surface on the second engagement formations is ramped so that the flanges and spool are drawn together in response to the relative rotation toward the locked position.

12. A reel assembly according to any one of claims 1 to 9 wherein both the engagement surface are correspondingly ramped for sliding surface to surface contact and so that the flanges and spool are drawn together in response to the relative rotation toward the locked position. SUBSTITUTE SHEET (RULE 26) WO 02/08107 PCT/AU01/00904 -14-

13. A reel assembly according to any one of the preceding claims wherein the engagement formations, locking catches and deflection surfaces are uniformly spaced around each end of the spool and correspondingly located on each flange.

14. A reel assembly according to any one of the preceding claims wherein at least one of the first engagement formations is directed radially inwardly from each end of the spool.

A reel assembly according to any one of the preceding claims wherein at least one of the first engagement formations is directed radially outwardly from each end of the spool.

16. A reel assembly according to any one of the preceding claims, including a plurality of the first engagement formations and deflection surfaces on each end of the spool, and a corresponding plurality of the second engagement formations and locking catches on each flange.

17. A reel assembly according to any one of the preceding claims wherein six first engagement formations are directed radially inwardly and six engagement formations are directed radially outwardly from each end of tte spool.

18. A reel assembly according to any one of the preceding claims wherein each of the flanges include an inner face having an annular recess to receive and locate the corresponding end of the spool.

19. A reel assembly according to any one of the preceding claims wherein the spool is formed from a plurality of elongate axially extending parallel segments. A reel assembly according to claim 19 wherein the segments are hingedly interconnected about substantially parallel hinge axis.

WO 02/08107 PCT/AU01/00904

21. A reel assembly according to claims 19 or 20 wherein adjacent segments are hingedly interconnected by means of a flexible wall extending between adjacent longitudinal edges.

22. A reel assembly according to claims 20 or 21 wherein the spool is formed in two sections, each comprising a series of the interconnected segments.

23. A reel assembly according to claim 22 wherein each section includes a tab extending circumferentially on one longitudinal edge adapted for locating engagement with a complementary aperture formed in the corresponding edge of the opposing section to positively locate the section halves to form the spool.

24. A reel assembly according to claims 22 and 23 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.

A reel assembly according to any one of claims 19 to 24 wherein the segments include longitudinal and transverse ribbing to enhance rigidity.

26. A reel assembly according to any one of the preceding claims wherein each flange includes a serrated tapered aperture adjacent the second locking formation for securing a cable end prior to winding the cable onto the reel.

27. A reel assembly according to any one of the preceding claims wherein each flange includes a relatively small aperture adjacent the second locking formation for securing small diameter cable prior to winding the cable onto the reel.

28. A reel assembly according to any one of the preceding claims wherein each flange includes periphery spaced apertures to facilitate cable tie off following winding of the cable onto the reel. WO 02/08107 PCT/AU01/00904 -16-

29. A reel assembly according to any one of the preceding claims wherein each flange includes a first alignment formation on the outer surface and a corresponding second alignment formation on the inner surface to facilitate stable stacking of multiple flanges. A reel assembly substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings.