US20070262192A1

US20070262192A1 - Storage and transport device for flexible material and method of making same

Info

Publication number: US20070262192A1
Application number: US11/879,722
Authority: US
Inventors: Thaddeus Derendal
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-02-06
Filing date: 2007-07-19
Publication date: 2007-11-15

Abstract

A storage and transport device for flexible material that allows for easy assembly by an individual, wherein the device includes a cylindrical core made of two identical tube portions which include several locking mechanism to join the tube portions, and a first flange connected to the top of the cylindrical core and a second flange connected to the bottom of the cylindrical core, wherein flexible material is wound or unwound around the core.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates generally to the field of material storage and to storage devices used for storage and transport of flexible materials, particularly cable, rope, hoses, wire or cord.
2. Description of the Related Art
Reels and similar devices comprise primarily a spool upon which flexible materials may be wound and stored or transported. The stored material is normally flexible enough to allow it to be wound around the spool. The addition of flanges attached to both ends of the spool prevents the material from falling off the edge of the spool, as well as aides in winding the material in the most efficient manner possible.
The need for spools is quite great, and a variety of materials are stored and subsequently transported on spools. Cables, ropes, hoses and wire are just a few examples of the materials, mechanisms and systems that benefit from the use of spools and similar storage devices. Currently, reels and spools are manufactured almost completely by companies that specialize in the manufacture of these devices. These reel producing companies typically manufacture the flanges, the spool or tube portions, and the fasteners that connect the flanges to the spool portion. These reel producing companies also typically provide the labor for assembly, and then ship the completed reels to the end user for their specific application.
Not surprisingly, reel manufacturing is limited by geographies and considering as fully constructed reels are extremely bulky, and there is no simple solution for long distance shipping within most businesses. In addition, companies that use reels typically do not assemble their own reels due to the number of variables and components required to manufacture customized reels.
Various solutions have been introduced attempting to simplify the problems associated with flexible material storage. For example, U.S. Design Pat. No. D370,908 to Weisburn et al., discloses an ornamental design for a tape reel flange. The drawings appear to illustrate levers along with tabs that include holes, ostensibly to lock the flange to a hub.
U.S. Pat. No. 3,239,159 to Cohen, discloses a tape-collecting reel designed to decrease inertia of the device by providing cut outs in the flange portion. The reel is designed to be assembled and disassembled quickly and easily by the removal of flange discs on either end of the reel. The flanges include keyholes that contain enlarged openings at the end of narrow slots. This arrangement allows a locking pin to be inserted, and then locked in place with rotation of the disc flange.
U.S. Pat. No. 5,114,089 to Posso, discloses another tape reel that includes detachable flanges and a means for locking the flanges to the hub. The locking mechanism comprises a series of axially positioned tabs that are placed over locking bars. By rotating the flange, the locking bars engage the tabs thereby locking the flanges in place.
U.S. Pat. No. 5,806,788 to Witwer, et al., discloses a so-called knockdown reel assembly. The term “knockdown” refers to the ability of the reel to be collapsed for easy storage and transport. The device includes a drum and end flanges that combine to form the reel. The end flanges include an interior disc portion that is attached to the flange. The drum segments then slide over and lock onto this disc portion of the end flanges to provide a locked assembly. The entire device may be made from any suitable lightweight plastic material.
U.S. Pat. No. 6,045,087 to Vislocky, et al., discloses a spool with snap fit flanges. The spool is capable of quick and easy assembly by means of locking tabs that will snap into place when properly aligned and inserted within receiving portions on the hub. The alignment of the flanges with the receiving portions is further simplified by means of a guide comprising a notch in the end of the hub that allows the flange to be inserted in only one position. This alignment tool is designed to take out any guesswork that might be involved with attaching the flange to the hub.
U.S. Pat. No. 6,089,500 to Häfner, discloses a collapsible spool that includes what are termed bayonet couplings. The couplings allow for easy assembly of the flanges to the hubs, simply by placing the flange on the hub, and rotating to a locked position. Additional stability can be achieved by inserting locking plugs into holes that will be available only when the flange is properly aligned with the hub in a locked position.
U.S. Pat. App. No. 2002/0053625 to Charlton, discloses a demountable cable reel that is also designed to provide quick and easy assembly and disassembly without having to remove the cable from the hub. This feature is particularly useful in the event that one of the flanges becomes damaged and must be replaced. The locking mechanism that this device employs is a fairly straightforward gear tooth style configuration. The portion resembling a gear is attached to the flange and inserted within a mirror-image style cut out of the gear. By rotating the flange, the extensions of the gear shaped element are thereby locked into position relative to the hub. A locking pin may also be employed for additional stability.
In summary, investigation of these disclosed devices illustrates that presently, there is no single device known in the art that meets the requirements of a storage and transport device for flexible material that includes the unique structure of the present invention, and its inherent benefits.

SUMMARY OF THE INVENTION

The present invention, as described further herein, imparts a novel storage and transport device for flexible material which encompasses the advantages of other flexible storage devices, but allows for on-site assembly by an individual, and also includes adjustable components to accommodate varying sizes of flexible material. The instant invention, as illustrated herein, is clearly not anticipated, rendered obvious, or even present in any of the prior art mechanisms, either alone or in any combination thereof. Therefore, what is required is a flexible material storage device that can be assembled quickly and easily by the end user.
The primary object of the present invention is to provide for a storage and transport device for flexible material that utilizes a unique locking arrangement for quick assembly, and a strong and stable structure.
Another object of the present invention is to provide for a storage and transport device for flexible material that allows for efficient bulk transfer of flexible material.
Another object of the present invention is to provide for a storage and transport device for flexible material that allows for simple and inexpensive assembly.
Another object of the present invention is to provide for a storage and transport device for flexible material that allows for shipment of flexible material in great quantities than devices known in the art.
Another object of the present invention is to provide for a storage and transport device for flexible material that allows for multiple devices to be stacked on top of one another for bulk shipment and storage.
Another object of the present invention is to provide for a storage and transport device for flexible material that requires minimal labor to assemble and put the device into use.
There has thus been outlined, rather broadly, the more important features of the storage and transport device for flexible material in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
These together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings, in which:
FIG. 1 is an exploded view of all aspects of the components prior to assembly of the storage and transport device for flexible material.
FIG. 2 is a diagrammatic perspective view of the one of the semi-circular tube portions that comprises the cylindrical core of the storage and transport device.
FIG. 3A is a diagrammatic perspective view of the two semi-circular tube portions prior to assembly and locking.
FIG. 3B is an exploded view of the locking mechanisms located on each of the semi-circular tube portions.
FIG. 4 is a top view of one of the flanges that is secured to one end of the cylindrical core of the storage and transport device for flexible material.
FIG. 5 is a diagrammatic perspective view of an assembled storage and transport device prior to rotation and locking of the flanges to the cylindrical core.
FIG. 6A is a diagrammatic perspective view of the assembly jig and assembly jig peg used for securing and locking the components of the storage and transport device for flexible material.
FIG. 6B is an exploded view of the assembly jig peg which works in conjunction with the assembly jig to secure one of the flanges during rotation and locking of the components of the storage and transport device for flexible material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a storage and transport device 10 for flexible material including, but not limited to rope, wire, cord, hose and cable. The device 10 includes a cylindrical core 12 having a first and second tube portion 14A and 14B (see FIG. 2 and FIG. 3A) that are held together by several locking mechanisms. It should be noted that first tube portion 14A and second tube portion 14B are identical and each includes the same components and locking mechanisms. Each tube portion 14A and 14B includes a top 16A and a bottom 16B. A first flange 18A is removeably attachable to the top portions 16A of the first and second tube portions 14A and 14B, and wherein a second flange 18B (see FIG. 3A) is removeably attachable to the bottom portions 16B of the first and second tube portions 14A and 14B. A base jig 20 is provided during assembly of the storage and transport device 10, holding the second flange 18B in position during rotation and locking of the cylindrical core 12 to the second flange 18B. In use, preferably the flexible material is wrapped around the cylindrical core 12 for storage and/or transport to an individual or company.
FIG. 2 illustrates first tube portion 14A which comprises one half of the cylindrical core 12. A plurality of top locking tabs 22 extend outwardly from the top 16A of each tube portion 14A and 14B, wherein, each top locking tab 22 includes a knob 24 protruding downwardly toward the second flange 18B. A plurality of top flexible retaining mechanisms 26 having a slot and groove 28A and a protrusion 28B located on the top 16A of each tube portion 14A and 14B are alternately disposed between the top locking tabs 22. A plurality of bottom locking tabs 30 extend outwardly from the bottom 16B of each tube portion 14A and 14B, wherein each bottom locking tab 30 includes a knob 32 protruding upwardly toward the first flange 18A. Preferably each top locking tab 22 and bottom locking tab 30, and each knob 24 and 32 is set at an angle in relation to each flange 18A and 18B to allow for easy assembly and locking of each flange 18A and 18B to the cylindrical core 12. A plurality of bottom flexible retaining mechanisms 34 having a slot and groove 36A and a protrusion 36B located on the bottom 16B of the each tube portion 14A and 14B, are alternately disposed between the bottom locking tabs 30. Preferably, there are two top and two bottom locking tabs 22 and 30, and two top and two bottom flexible retaining mechanisms 26 and 34, located on the each tube portion 14A and 14B. Preferably, each top locking tab 22 alternates and is equidistantly spaced along the top 16A of each tube portion 14A and 14B with each top flexible retaining mechanism 26. Likewise, each bottom locking tab 30 alternates and is equidistantly spaced along the bottom 16B of each tube portion 14A and 14B with each bottom flexible retaining mechanism 34.
The first and second tube portion 14A and 14B of the cylindrical core 12 each include a first end 36A and a second edge 36B, wherein both edges 36A and 36B extend between the top and bottom 16A and 16B of the tube portions 14A and 14B. The first and second tube portions 14A and 14B further include an exterior surface 38A and an interior surface 38B (see FIG. 3A), wherein the exterior surface, preferably includes a smooth texture. Alternatively, the exterior surface 38A is a rough texture. Preferably, the interior surface 38B includes variable inner surface structures such as ribs, to enhance strength and support of the first and second tube portions 14A and 14B. Alternatively, the interior surface 38B contains various truss structures used to enhance strength and support known in the art but not contemplated herein.
FIG. 3A illustrates the first and second tube portions 14A and 14B prior to assembly to form the cylindrical core 12. The first and second tube portions 14A and 14B each contain several locking mechanisms which allow the tube portions 14A and 14B to be joined together. A plurality of pins 40 and a plurality of hooked shaped peg receptacles 42 are located along the first edge 36A of each tube portion 14A and 14B, wherein each pin 40 alternates with each peg receptacle 42 along the first edge 36A. A plurality of pin receptacles 44 and a plurality of hooked shaped pegs 46 are located along the second edge 36A of each tube portion 14A and 14B, wherein each pin receptacle 44 alternates with each hooked shaped peg 46 along the second edge 36B. Furthermore, to ensure stability, strength and alignment of the hooked shaped pegs 46 with the hooked shaped peg receptacles 42, a plurality of guiding rails 48 are situated alongside the peg receptacles 42 and pegs 46. Therefore, in order to assemble the cylindrical core 12, the first edge 36A of the first tube portion 14A is aligned with the second edge 36B of the second tube portion 14A and the first edge 36A of the second tube portion 14B is aligned with the second edge 36B of the first tube portion 14A. This orientation allows for the plurality of pins 40 located on the first edge 36A of the first tube portion 14A to couple with the plurality of pin receptacles 44 located on the second edge 36B of the second tube portion 14B, and for the plurality of hooked shaped pegs 46 located on the second edge 36B of the second tube portion 14B to couple with the plurality of hooked shaped peg receptacles 42 located on the first edge 36A of the first tube portion 14A. Preferably, each pin receptacle 44 is beveled to ensure proper coupling with each pin 40.
FIG. 3B illustrates in detail one of the pins 40 and one of the peg receptacles 42 located on the first edge 36A of the first tube portion 14A mating with one of the pin receptacles 44 and one of the hooked shaped pegs 46 located on the second edge 36B of the second tube portion 14B.
FIG. 4 illustrates the first flange 18A having a plurality of locking tab receiving means 50, wherein each locking tab receiving means 50 aligns with and receives one of the top locking tabs 22. It should be noted that the first and second flange 18A and 18B are identical and have the same components and function. Furthermore, each locking tab receiving means 50 is equidistantly disposed around the first flange 18A. A pair of drive slots 52 are located on opposite sides of the first flange 18A to assist in the assembly of the storage and transport device 10 during rotation and locking of the first flange 18A to the cylindrical core 12, wherein a turning bar is used in conjunction with the drive slots 52 to rotate and lock each flange 18A and 18B to the cylindrical core 12. A plurality of knob receptacles 53 are equidistantly disposed around each flange 18A and 18B to receive and mate with each of the knobs 24 located on the top locking tabs 22 and each of the knobs 32 located on the bottom locking tabs 30. In the preferred embodiment, a center hole 54 is located on the first flange 18A, which allows an individual to place the storage and transport device 10 on a spindle to easily wind and unwind various flexible materials.
FIG. 5 illustrates the storage and transport device 10 fully assembled prior to rotation and locking of the first and second flanges 18A and 18B to the cylindrical core 12. In this embodiment, the first flange 18A is aligned with the top portions 16A of the first and second tube portions 14A and 14B that comprise the cylindrical core 12, such that the top locking tabs 22 are aligned with the tab receiving means 50 of the first flange 18A. Likewise the second flange 18B is aligned with the bottom portions 16B of the first and second tube portions 14A and 14B, such that the bottom locking tabs 24 are aligned with the tab receiving means 50 of the second flange 18B.
FIG. 6A illustrates the base jig 20 used during assembly of the storage and transport device 10. Preferably the base jig 20 is square in shape and includes a pair of assembly jig peg receptacles 54 for receiving a pair assembly jig peg 56 (see FIG. 6B), wherein the assembly jig pegs 56, couples with the drive slots 52 of either the first or second flange 18A and 18B to hold them in place during rotation and assembly of the storage and transport device 10. The assembly jig receptacles 54 allow for the assembly jig pegs 56 to be moved to varying distances to accommodate different sizes flanges depending on the type and amount of flexible material needed to be stored and/or transported.
FIG. 6B illustrates one of the assembly peg jigs 56, wherein the assembly peg jig 56 includes a base 58 that is preferably square in shape and a protrusion 60 extending upwardly from the base 58 and couples with one of the assembly jig peg receptacles 54 and one of the drive slots 52 to secure either the first or second flange 18A or 18B during rotation and assembly.
In operation, the cylindrical core 12 is assembled by securing the first and second tube portions 14A and 14B together via their respective edges 36A and 36B, and aligning each of the pins 40 with each of the corresponding pin receptacles 44, and aligning each of the hooked shaped pegs 46 with each the corresponding hooked shaped peg receptacles 42. Once the cylindrical core 12 is assembled via the above-referenced process, the second flange 18B is placed on the base jig 20 by aligning the drive slots 52 of the second flange 18B with the assembly peg jigs 56 located in the assembly jig receptacles 56. After the second flange 18B is secured in the base jig 20, the bottom portions 16B of the tube portions 14A and 14B that comprise the cylindrical core 12 are placed atop the second flange 18B, wherein each of the bottom locking tabs 30 are aligned with and placed into each of the corresponding locking tab receiving means 50. Once the second flange 18B is aligned with the bottom portions 16B, the first flange 18A is placed atop the top portions 16A of the cylindrical core 12, wherein each of the top locking tabs 22 are aligned with and placed into each of the corresponding locking tab receiving means 50 of the first flange 18A. Once the storage and transport device 10 is assembled in the above-referenced structure, the first flange 18A is rotated in the direction allowed by each of the locking tab receiving means 50, such that each of the knobs 24 couple with each of the corresponding knob receptacles 53. This allows the first flange 18A to be locked in place based on the locking aspects of the top locking tabs 22 through the top flexible retaining mechanisms 26. The second flange 18B is connected to the cylindrical core 12, in a similar fashion as the first flange 18A by rotating and locking the second flange 18B through the various locking mechanisms. Alternatively, a turning bar may be used to rotate and lock each flange 18A and 18B to the cylindrical core 12, by placing the turning bar in the drive slots 52 and rotating until each flange 18A and 18B is secured to the cylindrical core 12.
Once each storage and transport device 10 is assembled, the structure of each device 10, allows for multiple devices 10 to be stacked atop one another flush for more convenient storage and transport. This is accomplished by placed the second flange 18B of one assembled device 10 atop the first flange 18A of another assembled 10, wherein the bottom locking tabs 30 of the second flange 18B of one assembled device 10 are placed in the top locking tab receiving means 50 of the first flange 18A of another assembled device 10. The tab receiving means 50 contain a void after rotation and locking of each flange 18A and 18B to the cylindrical core 12, such that the tab receiving means 50 are able to couple with either the top or bottom locking tabs 22 and 30 of another assembled device 10.
The ease with which the present invention may be constructed should now be readily apparent. Many such devices may be shipped, disassembled in bulk to the end user. The device may then be easily and efficiently stored as desired, or put immediately into service with minimal labor. Cost will further be reduced because a larger number of disassembled devices may be shipped then assembled reel devices produced by other manufacturers. The size, both diameter and length of the device may be varied depending upon the application. In addition, a variety of materials may be utilized, including plastic molds for the tube portions, and flanges comprised of wood materials.
Although the present invention has been described with reference to particular embodiments, it will be apparent to those skilled in the art that variations and modifications can be substituted therefore without departing from the principles and spirit of the invention.

Claims

1. A storage and transport device for flexible material comprising:

a cylindrical core having a first tube portion and a second tube portion, wherein each tube portion includes a top and a bottom, and a first and a second edge, wherein each top includes a plurality of top locking tabs extending outwardly and a plurality of top flexible retaining mechanisms, wherein each top locking tab includes a knob protruding downwardly and each top flexible retaining mechanism includes a slot and groove and a protrusion, wherein each top locking tab alternates and is equidistantly disposed along the top with each top flexible retaining mechanism, and each bottom includes a plurality of bottom locking tabs extending outwardly and a plurality of bottom flexible retaining mechanisms, wherein each bottom locking tab includes a knob protruding upwardly and each bottom flexible retaining mechanism includes a slot and groove and a protrusion, wherein each bottom locking tab alternates and is equidistantly disposed along the bottom with each bottom flexible retaining mechanism, and wherein a plurality of pins are located along the first edge of each said first and second tube portion, and wherein a plurality of pin receptacles are located along the second edge of each said first and second tube portion; and

a first flange and a second flange, wherein each flange includes a plurality of locking tab receiving means, a plurality of knob receptacles and a pair of drive slots, where each locking tab receiving means couples with the corresponding locking tab of the cylindrical core, and wherein each knob receptacle couples with the corresponding knob located on each locking tab for coupling with the top and bottom locking tabs of the cylindrical core.

2. The storage and transport device of claim 1 further comprising a base jig, having a pair of assembly jig peg receptacles for receiving a pair of assembly jig pegs, wherein the assembly jig pegs couple with the drive slots of either the first or second flange to secure the device during assembly.

3. A method of assembling the storage and transport device of claim 1, the steps comprising:

forming the cylindrical core by aligning the first edge of the first tube portion with the second edge of the second tube portion so that the plurality of pins couple with the plurality of pin receptacles;

placing the cylindrical core atop the second flange by aligning the tab receiving means of the second flange with the bottom locking tabs;

placing the first flange atop the cylindrical core by aligning the tab receiving means of the first flange with the top locking tabs;

rotating the first flange in the direction allowed by each of the top locking tab receiving means so that each of the knobs couple with each of the corresponding knob receptacles; and

rotating the second flange in the direction allowed by each of the bottom locking tab receiving means so that each of the knobs couple with each of the corresponding knob receptacles.

4. A method of assembling the storage and transport device of claim 1, the steps comprising:

placing the second flange atop the base jig by aligning the pair of assembly jig pegs with the corresponding drive slots of the second flange through the jig peg receptacles of the base jig;

rotating the second flange in the direction allowed by each of the bottom locking tab receiving means so that each of the knobs couple with each of the corresponding know receptacles.

5. The method of claim 3 or 4, wherein a turning bar is used to rotate and lock the first and second flanges to the cylindrical core by engaging the drive slots of the first and second flange.

6. A method for stacking multiple storage and transport devices of claim 1, the steps comprising:

placing a first assembled storage and transport device on the ground; and

placing a second assembled storage and transport device atop the first assembled device by aligning the bottom locking tabs located on the second flange of the second assembled device with a void located in the tab receiving means on the first flange of the first assembled device so that the bottom locking tabs sit in the void allowing the first and second assembled device to be stacked flush against each other.

7. A storage and transport device for flexible material comprising:

a cylindrical core having a first tube portion and a second tube portion, wherein each tube portion includes a top and a bottom, and a first and a second edge, wherein each top includes a plurality of top locking tabs extending outwardly and a plurality of top flexible retaining mechanisms, wherein each top locking tab includes a knob protruding downwardly and each top flexible retaining mechanism includes a slot and groove and a protrusion, wherein each top locking tab alternates and is equidistantly disposed along the top with each top flexible retaining mechanism, and each bottom includes a plurality of bottom locking tabs extending outwardly and a plurality of bottom flexible retaining mechanisms, wherein each bottom locking tab includes a knob protruding upwardly and each bottom flexible retaining mechanism includes a slot and groove and a protrusion, wherein each bottom locking tab alternates and is equidistantly disposed along the bottom with each bottom flexible retaining mechanism, and wherein a plurality of pins and a plurality of hooked shaped peg receptacles are located along the first edge of each tube portion, wherein each pin alternates with each hooked shaped peg receptacle along the first edge of each said first and second tube portion, and wherein a plurality of pin receptacles and a plurality of hooked shaped pegs are located along the second edge of each said first and second tube portion, wherein each pin receptacle alternates with each hooked shaped peg along the second edge, and wherein each hooked shaped peg and hooked shaped peg receptacles contain a plurality of guiding rails for alignment; and

8. The storage and transport device of claim 7 further comprising a base jig used during assembly, having a pair of assembly jig peg receptacles for receiving a pair of assembly jig pegs, wherein the assembly jig pegs couple with the drive slots of either the first or second flange to secure the device during assembly.

9. The storage and transport device of claim 9, wherein each top locking tab and bottom locking tab, and each knob is set at an angle in relation to each flange to allow for easy assembly and locking of each flange to the cylindrical core.

10. A method of assembling the storage and transport device of claim 7, the steps comprising:

forming the cylindrical core by aligning the first edge of the first tube portion with the second edge of the second tube portion so that the plurality of pins couple with the plurality of pin receptacles and the plurality of hooked shaped pegs couple with the plurality of hooked shaped peg receptacles;

11. A method of assembling the storage and transport device of claim 7, the steps comprising:

12. The method of claim 9 or 10, wherein a turning bar is used to rotate and lock the first and second flanges to the cylindrical core by engaging the drive slots of the first and second flange.

13. A method for stacking multiple storage and transport devices of claim 7, the steps comprising:

placing a first assembled storage and transport device on the ground; and