US20130015287A1

US20130015287A1 - Spirally wound channel core

Info

Publication number: US20130015287A1
Application number: US13/182,833
Authority: US
Inventors: J. Daniel Bryant; Mark D. Crowley; Daniel Bergstrom; Stephen J. Makosey; Glenn W. Jarvis
Original assignee: Alcoa Inc
Current assignee: Howmet Aerospace Inc
Priority date: 2011-07-14
Filing date: 2011-07-14
Publication date: 2013-01-17
Also published as: CN202988421U; WO2013009842A1

Abstract

A spool has a spirally-wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web. The channel is oriented with the pair of arms parallel to the axis of the spool and with the central web extending radially, relative to the axis of the spool. The channel has a plurality of adjacent windings, a first and second of the arms of spirally-wound channel cumulatively forming the inner and outer surfaces of the spool. The arms are spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is received between the arms of adjacent windings and is retained therein to establish an overlap of windings in the axial direction. Other embodiments feature S, B and E-shaped channels to form the spool, some embodiments having inner and outer layers of channel. The spool is suitable for holding wound, thin metal stock, such as aluminum for making beverage cans, having a smooth outer surface which preserves the smoothness of the wound stock.

Description

FIELD

The present invention relates to spools or “cores” around which thin stock materials, such as sheet metal, metal foil, wire, fabric or rope, may be wound to allow storage, transportation and/or handling of such stock materials, and more particularly, to such spools made from spirally wound material.

BACKGROUND

Coiled products, such as aluminum sheet and foil, must be stored on and transported to customers using a central spool or core about which the product is wrapped. The dimensions and characteristics of such cores are generally specified by the customers, and must be compatible with the customers' coil handling systems and minimize product damage during shipping and handling. For example, for high-volume, coiled aluminum sheet products, such as can stock, end stock and tab stock (all used in the manufacture of the aluminum beverage can), the cores used are typically thick walled tubes of laminated Kraft paper. Alternatives to paper cores, e.g., metal cores constructed by overlapping a corrugated strip into a spiral form around a mandrel are known.

SUMMARY

The disclosed subject matter overcomes the disadvantages and shortcomings of the prior art by providing a spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound. The spool has a spirally wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool. The channel has a plurality of adjacent windings, a first of the arms of spirally wound channel cumulatively forming the outer surface and a second of the arms of spirally wound channel cumulatively forming the inner surface, the first arm and the second arm spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is receivable between the arms of adjacent windings and is retainable therein to establish an overlap of windings of the channel in the axial direction.
In accordance with an embodiment of the present disclosure, each of the first arm and the second arm has a first portion extending from the central web and a second portion extending from a free end of the arm to a transition portion extending between the first portion and the second portion, the second portion of the first arm and the second portion of the second arm having a first spacing there between approximating a second spacing between an exterior surface of the first portion of the first arm and an exterior surface of the first portion of the second arm.
In accordance with another embodiment of the present disclosure, the channel exhibits a third spacing between an exterior surface of the second portion of the first arm and an exterior surface of the second portion of the second arm and the difference between the second spacing and the third spacing approximates a radial thickness of the second portion.
In accordance with another embodiment of the present disclosure, the outer surface of the spool is cylindrical and smooth.
In accordance with another embodiment of the present disclosure, at least one of the first arm and the second arm has an undulating form in cross-section, an interior surface of the undulating form engaging and mating with an exterior surface of an undulating form of an adjacent winding of the channel of the spool.
In accordance with another embodiment of the present disclosure, both of the first arm and the second arm have an undulating form in cross-section.
In accordance with another embodiment of the present disclosure, the undulating form has first and second bulges separated by a valley, the first bulge extending from the central web.
In accordance with another embodiment of the present disclosure, the channel has at least one slot extending into the central web, the slot capable of receiving an end of at least one of the first arm and the second arm of an adjacent winding of the channel.
In accordance with another embodiment of the present disclosure, the slot is blind and is angled at an acute interior angle relative to the central web.
In accordance with another embodiment of the present disclosure, the channel has a pair of slots, a first slot disposed proximate a junction of the first arm with the central web and a second slot disposed proximate a junction of the second arm with the central web.
In accordance with another embodiment of the present disclosure, the first arm and the second arm each have an angled portion proximate a free end thereof which inserts into a corresponding one of the first slot and the second slot of an adjacent winding of the channel.
In accordance with another embodiment of the present disclosure, the channel has at least one groove in at least one of the first arm and the second arm disposed proximate the central web, and wherein at least one of the first arm and the second arm has an angled portion proximate a free end thereof which inserts into the groove of an adjacent winding of the channel.
In accordance with another embodiment of the present disclosure, the at least one groove is disposed between the central web and the first arm.
In accordance with another embodiment of the present disclosure, the at least one groove has a generally V-shaped cross-section.
In accordance with another embodiment of the present disclosure, at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.
In accordance with another embodiment of the present disclosure, a spool has an axis, an axial length, an inner surface and a curved outer surface about which material may be wound and a spirally wound, elongated channel having an S-shaped cross-section with a pair of arms extending from a central web and having a component of extension in opposite directions. A first arm of the pair of arms has a first extension extending from an end of the first arm distal to the central web at an angle relative to the first arm and forming a top portion of the S-shape. A second arm of the pair of arms has a second extension extending from an end of the second arm distal to the central web at an angle relative to the second arm and forming a bottom portion of the S-shape, the second extension pointing towards a portion of the central web. A distal end of the second extension is distal to the second arm and is spaced from the central web by a first spacing, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool. The channel has a plurality of adjacent windings, the first arm of adjacent windings of spirally wound channel cumulatively forming the outer surface and the second arm of adjacent windings of spirally wound channel cumulatively forming the inner surface, the first extension being receivable between the distal end of the second extension and the central web of an adjacent winding to interlock therewith and establish an overlap in the axial direction.
In accordance with another embodiment of the present disclosure, the distal end of the second extension pushes the first extension of an adjacent winding of the channel toward the central web.
In accordance with another embodiment of the present disclosure, a pushing arm extending from the distal end of the second extension, the pushing arm being captured in the interior angle formed between the first extension and the first arm.
In accordance with another embodiment of the present disclosure, a spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound has a spirally wound, elongated inner channel with a first central web and a first pair of arms spaced a first distance from one another. The inner channel is oriented with the first central web having a component of extension parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool. The inner channel has a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface. A spirally wound, elongated outer channel has a second central web and a second pair of arms spaced a second distance from one another. The outer channel is oriented with the second central web generally parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool. The outer channel has a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface. The outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.
In accordance with another embodiment of the present disclosure, the first pair of arms converge towards one another at a distal end thereof and the second pair of arms converge towards one another at a distal end thereof, the first pair of arms with the first central web forming a triangular shape and the second pair of arms with the second central web forming a triangular shape.
In accordance with another embodiment of the present disclosure, a first arm of a first adjacent winding of the outer channel and a second arm of a second adjacent winding of the outer channel are disposed within a first triangular shape of a first adjacent winding of the inner channel.
In accordance with another embodiment of the present disclosure, a plurality of adjacent windings of the inner channel each capture the first arm and the second arm of adjacent windings of the outer channel within the triangular shape, thereby interlocking the inner channel and the outer channel.
In accordance with another embodiment of the present disclosure, a plurality of adjacent windings of the outer channel each capture the first arm and the second arm of adjacent windings of the inner channel within the triangular shape, thereby interlocking the inner channel and the outer channel.
In accordance with another embodiment of the present disclosure, the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable.
In accordance with another embodiment of the present disclosure, the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.
In accordance with another embodiment of the present disclosure, the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm. The groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable. The outer channel having a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.
In accordance with another embodiment of the present disclosure, the outwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the outer channel and the inwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the inner channel.
In accordance with another embodiment of the present disclosure, at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.
In accordance with another embodiment of the present disclosure, a spool has an axis, an axial length, an inner surface and a curved outer surface about which material may be wound.
A spirally wound, elongated inner channel has a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool. The inner channel has a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface. A spirally wound, elongated outer channel has a second central web and a second pair of arms spaced a second distance from one another, The outer channel is oriented with the second central web parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool. The outer channel has a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface. At least one of the first arm and the second arm of at least one of the inner channel and the outer channel being scrolled inwardly toward the central web.
In accordance with another embodiment of the present disclosure, both the first arm and the second arm of at least one of the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape.
In accordance with another embodiment of the present disclosure, both the first arm and the second arm of both the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape, at least one of the inner channel and the outer channel having a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween.
In accordance with another embodiment of the present disclosure, both the inner channel and the outer channel have a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween. The outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.

FIG. 1 is a diagrammatic sequence showing the transition of a flat strip into a modified C-shaped channel through a sequence of bending steps in accordance with an embodiment of the present disclosure.

FIG. 2 is a perspective, partially diagrammatic view of the fabrication of a spirally wound core in accordance with an embodiment of the present disclosure.

FIG. 3 is a cross-sectional view of the spirally wound core of FIG. 2 taken along section lines III-III and looking in the direction of the arrows.

FIG. 4 is a cross-sectional view of a spirally wound core like that of FIG. 3, but utilizing a channel shape in accordance with another embodiment of the present disclosure.

FIG. 5 is a cross-sectional view of a spirally wound core like that of FIGS. 2 and 3, but utilizing a channel shape in accordance with another embodiment of the present disclosure.

FIG. 6 is a diagrammatic sequence showing the transition of a flat strip into a modified C-shaped channel through a sequence of bending steps and the winding of the resultant C-channel on a mandrel, in accordance with another embodiment of the present disclosure.

FIG. 7 is partially diagrammatic view of two steps in the sequence of the fabrication of a spirally wound core using the modified C-channel of FIG. 6 in accordance with an embodiment of the present disclosure.

FIG. 8 is a diagrammatic sequence showing the transition of a flat strip into a modified C-shaped channel through a sequence of bending steps in accordance with an embodiment of the present disclosure.

FIG. 9 is a perspective view of a modified C-channel in accordance with an embodiment of the present disclosure.

FIG. 10 is a cross-sectional view of a spirally wound core like that of FIGS. 2 and 3, but utilizing a channel shape as shown in FIG. 9.

FIG. 11 is a diagrammatic view of an apparatus for forming a spirally wound core from channel in accordance with an embodiment of the present disclosure.

FIG. 12 is a cross-sectional view of internal windings of a spirally wound composite core in accordance with another exemplary embodiment of the present disclosure.

FIG. 13 is a cross-sectional view of a spirally wound composite core of FIG. 12, but including exterior windings.

FIG. 14 is a cross-sectional view of a spirally wound composite core in accordance with another exemplary embodiment of the present disclosure and positioned on a mandrel.

FIG. 15 is a cross-sectional view of a spirally wound composite core showing interior and exterior windings in accordance with another exemplary embodiment of the present disclosure.

FIG. 16 is a cross-sectional view of a spirally wound composite core showing interior and exterior windings in accordance with another exemplary embodiment of the present disclosure.

FIG. 17 is a cross-sectional view of a spirally wound core made from modified channel in accordance with another exemplary embodiment of the present disclosure.

FIG. 18 is a cross-sectional view of a spirally wound core made from modified channel in accordance with another exemplary embodiment of the present disclosure.

FIG. 19 is a diagrammatic view of a structure for securing adjacent channels of a spirally wound core.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG. 1 shows an end-on view of a strip 10, e.g., made from a metal like aluminum, brass, copper or a polymer. In the case of a metal strip 10, the strip 10 is bent continuously or in a sequence of steps into a modified strip or pre-form 12, which, in cross-section (or as seen from an end-on view), has a recessed central web 14 from which extends a pair of straight extensions 16, 18.
The pre-form 12 is then bent (as shown by arrows A, B, C, D) into a modified C-shaped channel 20, which in cross-section, has two arms 22, 24 co-extensively extending away from the central web 14 in the same direction, approximately perpendicular thereto. Opposing end portions 22 a, 24 a of the web 14 of the pre-form 12, when bent, form portions of the arms proximate the central web 14, which have a spacing S1 between the outer surfaces of end portions 22 a, 24 a, approximating the interior spacing S2 between the arms 22, 24 proximate the opening of the C-shape. This bending to transition between the strip 10, to the pre-form 12, to the C-channel 20, can be accomplished by passing the strip 10 through roller dies (not shown) or a pulling it through a lubricated stationary die (not shown) or by or other conventional metal forming methods.
In the case of plastic, the C-channel 20 can be formed as a continuous extrusion from a melt or formed from a strip 10 that is deformable and settable, e.g., a thermoplastic via the application of bending and heating.
FIG. 2 shows the formation of a spirally wound core 26. More particularly, the C-shaped channel 20 is oriented with the arms 22, 24 approximately parallel to the outer cylindrical surface 28 s of a mandrel 28 and is wound about the mandrel 28 or otherwise urged (e.g., by a set of roller dies configuring a virtual mandrel) into a spiral shape. As successive turns/ windings 20 a, 20 b, . . . 20 x of the spirally wound C-shaped channel 20 are wrapped about the mandrel 28, the open end of the C-shape defined by the spaced arms 22, 24 (with spacing 52) is pushed over the central web 14 and the portions 22 a, 24 a of the arms 22, 24 (with a spacing S1 separating the outer surfaces thereof) of the C-channel 20 already wound on the mandrel 28, such that succeeding windings, e.g., 20 b of the C-channel 20 overlap and grip previous windings, e.g., 20 a, at the overlap, via friction, surface features or adhesive.
A guide roller 30 urged by force E, e.g., exerted via a resilient member or hydraulic actuation, may optionally assist in pressing the succeeding windings 20 a, 20 b . . . 20 x of the C-channel 20 into an overlapping relationship to form the core 26. Alternatively, a guide surface tapering toward the core 26 and urging the C-channel 20 in the direction indicated by force E, may be used. A counteracting force F may be applied by a spring-loaded, rotatable, axially displaceable plate 311 (See FIG. 11) to oppose the force E, to compress the adjacent turns 20 a, 20 b . . . 20 x into overlapping engagement. Alternatively, the core 26 may be compressed by an assembly of rolls. As a further alternative, the C-channel 20 may be partially or completely pre-bent into an arc (to form the spirally wound cylindrically-shaped core 26) by bending rollers, such as 32 a, 32 b, 32 c. After a given length of core 26 has been built up from the winding of C- channel 20 a, 20 b . . . 20 x, a saw 34, a cutting torch (not shown) or other cutting apparatus, is used to separate a portion of core 26 from the remainder present on the mandrel 28 allowing continuous winding of C-channel 20 and the cutting of successive segments of core 26 for a given application, e.g., for use as spools to wind sheet aluminum.
FIG. 3 shows a portion of a wall 36 of the core 26 in cross-section, showing a plurality of side-by-side, overlapping C- channel windings 20 a, 20 b . . . 20 x with the outer arms 24 a . . . 24 x forming an outer surface 38 of the wall 36 of the core 26 (See FIG. 2) and the inner arms 22 a . . . 22 x forming an inner surface 40 of the wall 36 of the core 26. Each of the C-channel windings 20 a . . . 20 x either overlap, are overlapped, or both, by an adjacent channel winding(s) 20 b . . . 20 x−1. The extent of one overlap 42 x (of channel winding 20 x and 20 x−1) is depicted in dotted lines. The webs 14 a . . . 14 x provide a radially extending support, which resists radial forces exerted on the core 26. FIG. 3 illustrates that the outer surface 38 and the inner surface 40 are substantially continuous and flat, interrupted only by the joints between adjacent C-channel turns 20 a . . . 20 x. The joints may be minimized by the geometry of the C-channel 20 (to provide a mating fit at the overlap 42) and by the degree that the overlapping C-channel windings 20 a . . . 20 x are pushed (compressed) into proximity.
FIGS. 4 and 5 illustrate that the dimensions of the C-channel 20 may be varied to adjust the attributes of the resultant core 26. More specifically, FIG. 4 shows that the length of arms 22′ and 24′ may be reduced relative to arm portions 22 a′ and 24 a′ (e.g., in comparison to the relative sizing shown in FIGS. 1 and 3), such that a given length of wall 36′ has more C-channel windings 20 a′ . . . 20 x′ and a greater number of webs 14′ providing support in a radial direction, given a similar overlap 42′.
FIG. 5 shows that the overlap 42″ may be increased by enlarging the length of the arm portions 22 a″ and 24 a″ relative to the length of the arms 22″ and 24″, the overlap 42″representing a double thickness of C-channel 20″ in the area of the wall 36″ defined by the overlap 42″.
FIG. 6 shows an end-on view of a strip 110, e.g., made from materials and by methods similar to those described above with respect to the embodiment shown in FIG. 1. The strip 110 may be bent continuously, or in a sequence of steps, into a modified strip or pre-form 112, which, in cross-section (or as seen from an end-on view), has a recessed central web 114 from which extends a pair of faceted extensions 116, 118. The pre-form 112 is then bent into a modified C-shaped channel 120, which, in cross-section, has two undulating arms 122, 124 co-extensively extending away from the central web 114 in the same general direction, approximately perpendicular thereto. The undulating arms 122, 124 of the C-channel 120 each have a pair of outwardly directed bulges 122 a, 122 b and 124 a, 124 b, respectively. A first bulge 122 a, 124 a, respectively, is near the central web 114 and a second bulge 122 b, 124 b, respectively, is near the open end of the C-shape and separated from first bulge 112 a, 124 a by an inwardly directed bulge 122 c, 124 c, respectively.
The C-channel 120 is oriented with the arms 122, 124 generally parallel to the outer cylindrical surface of a mandrel 128 and is wound about the mandrel 128 or otherwise urged (e.g., by a set of roller dies configuring a virtual mandrel) into a spiral shape. As shown in FIG. 7, as successive turns of the spirally wound C-shaped channel 120 are wrapped about the mandrel 128, the open end of the C-shape (defined by the spaced, undulating arms 122, 124) is pushed over the central web 114 of a portion of the C-channel 120 already on the mandrel 128, in a manner similar to that described above relative to FIG. 2, such that succeeding windings of the C-channel 120 overlap. FIG. 7 shows the overlapping of C- channel windings 120 a and 120 b to form a portion of a wall 136 of a core like wall 36 of core 26 of FIG. 2, but utilizing the C-channels 120 of FIG. 6.
As shown in FIG. 7, the second bulges e.g., 122 b, 124 b of each C-channel winding 120 a, 120 b . . . 120 x has a shape similar to the first bulges e.g., 122 a, 124 a, but is dimensioned such that the open end of the C-shape of the C- channel windings 120 a, 120 b allows easy insertion of the central web 114 of an adjacent turn of the C-channel, e.g., 120 a therein, to build-up a spirally wound core, i.e., dimension S1 is less than S2.
As shown in FIG. 7, subsequent to the insertion/overlapping of adjacent turns of the C- channel 120 a, 120 b . . . 120 x, the second bulges 122 b, 124 b of each of the arms 122, 124, respectively, of the C-channels 120 a . . . 120 x are urged towards each other by a set of roller dies 144, 146 or equivalent means to clamp the over-lapping second bulges 122 b, 124 b of a given C-channel, e.g., 120 b, over the first bulges 122 a, 124 a of the adjacent C-channel turn, e.g., 120 a, locking the adjacent turns 120 a, 120 b together to resist disassociation by forces exerted on the resultant winding core (like 26 of FIG. 1) in a direction parallel to the axis of the core 26. The over-lapping second bulges 122 b, 124 b are dimensioned and shaped such that when they are clamped over the first bulges 122 a, 124 a, the mating surfaces thereof are complementarily shaped and substantially parallel.
FIG. 8 shows an end-on view of a strip 210, e.g., made from materials and by methods similar to those described above with respect to the embodiment shown in FIGS. 1-7. The strip 210 may be bent continuously or in a sequence of steps into a series of modified strips or pre-forms 212 a-212 e and finally, into a modified C-shaped channel 220. The C-channel 220 has a central web 214 bounded by two angled slots 215, 217, formed by walls 215 a, 215 b, 215 c and 217 a, 217 b and 217 c, respectively. Two arms 222, 224 extend away from the slot walls 215 c and 217 c, respectively, generally co-extensively and perpendicular to the web 214 and in the same general direction. The arms 222, 224 each have an inwardly directed lip 223 and 225, respectively, at the open end of the C-shape, having an angle relative to a corresponding arm 222, 224 approximating that of the slots 215, 217.
FIG. 9 shows the C-channel 220 prior to bending. As in the above-described embodiments, the C-channel is oriented with the arms 222, 224 generally parallel to the outer cylindrical surface of a mandrel 28 and is wound about the mandrel 28 or otherwise urged (e.g., by a set of roller dies 32 a-32 c configuring a virtual mandrel) into a spiral shape.
FIG. 10 shows that as successive turns of the spirally wound C- channel 220 a, 220 b . . . 220 x are wrapped about the mandrel 228, the inwardly directed lips, e.g., 223 b, 225 b proximate the open end of the C-channel 220 b are urged/guided into the angled slots 215 a, 217 a in the central web 214 a portion of the C-channel 220 a already on the mandrel 228 by temporary deformation, followed by relaxation of the deformation to allow a return to an un-deformed configuration via elastic memory. As elastic memory exerts itself, the lips, e.g., 223 b, 225 b converge towards one another in the respective slots 215 a, 217 a and pull successive windings of the C-channel 220 a . . . 220 x toward one another in a self-induced elastic compression. The temporary deformation of the lips 223, 225 and arms 222, 224 may be done by roller guides or stationary tapered dies that guide a C-channel 220 into the deformed position at the time it encounters the mating slots.
Optionally, the slots 215, 217 may be crimped down onto the inwardly directed lips 223, 225 by a die acting internally to the C-channel 220 b as it is coupled to the prior winding of C-channel 220 a, i.e., by pressing against central web 214 a. Crimping may also be accomplished by a crimping roller pressing the windings 220 a . . . 220 x against the mandrel 228 to diminish the distance between walls 222, 224, either independently, or in combination with crimping by an internal die.
FIG. 11 shows an apparatus 300 for forming cores 326 from C- channel 20, 120, 220. More particularly, a mandrel 328 is turned by a motor 301 or other drive means, pulling C-channel strand 320 onto the mandrel 328. In order to start the continuous production of cores 326, the strand must be clamped to the mandrel 328 until sufficient frictional interaction exists between the strand 320 and the mandrel 328 to draw and bend the strand over the mandrel 328. As the strand of C-channel 320 is drawn onto the mandrel 328, one or more rollers 330 a, 330 b push successive windings of C-channel into overlapping condition, as described above. The formative, continuous core 326 f may be supported on the mandrel 328 and or rotated with the mandrel by rollers 303, 305 that may be driven or free turning. Brakes 307, 309 may be utilized to restrain the axial movement of the formative core 326 f to allow compression of the C-channel windings and/or stop the rotation of the mandrel 328 to allow cutting of a core 326 from the formative core 326 f by cutter 334. Alternatively, a core restraint 311, which is selectively rotatable and projectable/retractable in an axial direction, may be used to press against the formative core 326 f to promote compression of the C-channel windings and/or to apply a braking force to stop the core 326 f for cutting. As a further alternative, cores 326 may be cut from the formative core 326 f as the formative core 326 f is turned, e.g., by a cutting torch that is moved axially to compensate for the axially advancing formative core 326 f, in order to make a straight cut.
FIGS. 12 and 13 show an alternative embodiment of the present disclosure having a core 426 with a wall 436 formed from interior windings 420 a . . . 420 x and exterior windings 431 a . . . 431 x−1 of C-channel (420 and 431 generally, respectively) shown in cross-section and wound on a mandrel 428, an outer surface 428S of which is depicted by a dotted line. The C- channel 420 and 431 may optionally be identical, but oriented in opposite orientations when wound. The C-channel 420 is wound with the central web 414 thereof oriented generally parallel to the outer surface 428S of the mandrel 428. The arms 422, 424 of the C-channel 420 extend away from the mandrel 428 and are bent toward one another (as shown by the arrows on arms 422 x and 424 x of winding 420 x in FIG. 12) either before being wound on the mandrel or afterward, to form an open triangular shape in cross-section (see 420 a . . . 420 x−1 in FIG. 12). As shown in FIG. 13, outer windings 431 a . . . 431 x−1 of C-channel 431 are wound about the interior windings 420 a . . . 420 x with the arms 433, 435 (See e.g., 431 x−1) pointed toward the mandrel 428 and positioned between the open triangular shape of two adjacent interior windings 420. Subsequent to the winding of the outer C-channel 431 onto the interior C-channel 420, in the bridging configuration shown, the arms 433, 435 of the outer C-channel 431 and the arms 422, 424 of the inner C-channel 420 are bent to approximate a triangular shape (relative to respective webs 437, 414), interlocking the spirally wound C- channels 420, 431. The webs 437 a . . . 437 x−1 form the exterior wall surface 439 and the webs 414 a . . . 414 x form the interior wall surface 441 of the core 426. The bending of the respective C- channels 420, 431 into a triangular cross-sectional shape may be facilitated by compressing the outer surface 439 toward the inner surface 441. Displacements of the C- channels 420, 431 in a compressive direction are limited by the arms 422, 424, 433, 435 of the respective channels 420, 431 reaching a limit of travel at respective interior acute angles of the triangularly-shaped, mating C-channel.
FIG. 14 shows an alternative embodiment of the present disclosure for making a core 526 on mandrel 528 with a wall 536 formed from interior windings 550 a . . . 550 x−1 and exterior windings 550 a′ . . . 550 x−1′ of E-channel (550 and 550′ generally, respectively, with exterior windings 550 a′ . . . 550 x−1′ shown in phantom) wound on a mandrel 528, having an outer surface 528S. The E-channel 550 has a pair of arms 553, 555 extending from corresponding web portions 557, 559. A central U-portion 561 defines a central cavity 563. A pair of return U-portions 565, 567 connect the central U-portion 561 to the web portions 557, 559, respectively. The E-channel 550 and 550′ may optionally be identical and have the same type of arms, 553, 555, web portions 557, 559, U-portion 561 and return U-portions 565, 567, but oriented oppositely when wound to form the core 526. While the E-channel 550, 550′ depicted in FIG. 14 is symmetrical about the U-portion 561, which is denominated a “central U-portion,” optionally, the U-portion 561 could be shifted off-center, such that web portions 557 and 559 would be of unequal length.
The E-channel 550 is wound with the web portions 557, 559 thereof oriented generally parallel to the outer surface 5285 of the mandrel 528 a and with the arms 553, 555 extending away from the mandrel 528. Successive windings 550 a, 550 b, 550 x−1, etc. are wound in close proximity, one to another, such that the arms, e.g., 553 b, 555 a of adjacent E channel windings 550 a and 550 b touch, or are closely spaced. Since the core 526 shown in FIG. 14 is a spirally wound structure, the lower portion of the core 526 on the mandrel 528 has the same structures that are present on the opposite side of the core 526, displaced axially. Once the inner windings 550 a . . . 550 x−1 are wound onto the mandrel 528, outer windings 550 a′ . . . 550 x−1′ of E-channel 550′ are wound about the interior windings 550 a . . . 550 x with the arms 553′, 555′ pointed toward the mandrel 528 and positioned to be received in the central cavity 563 of central U-portions 561 of the inner windings of E-channel 550 already on the mandrel 528. For example, arm 555 a′ of winding 550 a′ is received in central cavity 563 a of E-channel 550 a. Simultaneously, arm 555 a of winding 550 a and arm 553 b of winding 550 b are received in central cavity 563 a′ of outer winding 550 a′. Central cavity 563 a′ may optionally be dimensioned to squeeze arms 553 b and 555 a together and the U-portions 563 a′, 565 a′ and 567 a′ may exhibit elasticity to enable deformation of U-portion 563 a′ to accommodate arms 553 b and 555 a, which are then urged together under the influence of elastic memory. This relationship between arms 553, 555 and U-portion 561 is exhibited along the width of the core 526, alternatively, by the inner and outer windings of E-channel 550, 550 a, drawing the core 526 into axial compression. The webs 557′ and 559′ form the majority of the exterior wall surface 539 and the webs 557 and 559 form the interior wall surface 541 of the core 526. In the case of both the outer wall surface 539 and the inner wall surface 541, the central U-portions 561 and central U-portions 561′ form a minor portion of the respective surfaces. The overlaying/meshing of the respective E-channels 550, 550′ may be facilitated by compressing the outer surface 539 toward the inner surface 541, e.g., with a press roller or tapered guide surface (not shown) or by exerting a tension on the E-channel 550′ as it is wound to make the core 526. The length of the arms 553, 555 and web portions 557, 559 can be varied to provide a selected number of radial supports for a given length of core 526 and for controlling the wall 536 thickness, each mating junction of arms, e.g., 553, 555 with central U-portions 561′ and return U-portions 565′, 567′ providing six radial support members.
FIG. 15 shows an alternative embodiment of the present disclosure wherein a core 626 has a wall 636 formed from inner and outer windings, e.g., 670 a, 670 a′ of B-channel 670. The B-channel 670 has a central web 672 bounded by end scrolls 674, 676. The interior windings 670 a . . . 670 d of B-channel 670 are spirally wound on a mandrel 628—like mandrel 528 of FIG. 14, with the web, e.g., 672 a facing the mandrel and the scrolls, e.g., 674 a, 676 a pointing away from the mandrel 628. One or more exterior windings 670 a′ . . . 670 c′ of exterior B channel 670 are wound over the interior B-channel 670 with the webs 672 a′ . . . 672 c′ thereof pointed away from the mandrel 628 and the scrolls, e.g., 674 a′ and 676 a′ pointed toward the mandrel 628. As shown, the scrolls 674 a′ . . . 674 c′ and 676 a′ . . . 676 e of the outer windings 670 a′ . . . 670 c′ insert between the scrolls 674 a . . . 674 d and 676 a . . . 676 d of the inner windings 670 a . . . 670 d, each bridging the adjacent windings of the other and with the scrolls interleaved. For example, outer winding 670 a′ bridges adjacent inner windings 670 a and 670 b, with scroll 676 a′ inserted between scrolls 674 a and 676 a interleaved with scroll 674 a. Scroll 674 a′ is interleaved with scroll 676 b of inner winding 670 b. The composite core 626 has an inner wall surface 641 formed by the webs 672 a . . . 672 d of the interior B-channel windings 670 a . . . 670 d and an exterior surface 639 formed by the webs 672 a′ . . . 672 e of the exterior windings 670 a′ . . . 670 e of the B-channel 670. In this embodiment, as in other embodiments of the present disclosure, the exterior windings 670 a′ . . . 670 c′ of the B-channel 670 and/or the interior windings 670 a . . . 670 d of the B-channel 670 may be secured to one another by welding, riveting, adhesives or fasteners at one or more locations, e.g., at the ends, to prevent unwinding.
FIG. 16 shows an alternative embodiment of the present disclosure similar in some ways to that of FIG. 15, in that the inner B-channels 770 a . . . 770 c are similarly dimensioned as the exterior B-channels 774 a . . . 774 c, e.g., identical, but reversed in orientation during winding. The distance W3 between the scrolls 777, 779 may optionally be approximately twice that of the width W4 of the scrolls 777, 779, such that the scrolls 777, 779 of adjacent interior B-channels 770 may be accommodated between the spacing of width W3 between scrolls of an exterior B-channel and vice versa, without interleaving. The scrolls, e.g., 777, 779 of the B-channel 774, provide radial reinforcement of the core 726 when wound to form composite wall 736, but also retain elasticity since the scrolls 777, 779 are not attached to web 775, lending resistance to radial deformation of the core 726, as well as a degree of elasticity permitting deformation and recovery after deforming forces are removed.
FIG. 17 shows an alternative embodiment of the present disclosure having a core 826 with a wall 836 formed from a spirally wound, modified S-channel 827. The core 826 is wound around a mandrel 828, as in previously described embodiments. The S-channel, in cross-section, features a central web 814 from which extends top arm 822 and bottom arm 824, the bottom arm 824 extending away from the central web 814 in a substantially opposite direction compared to the top arm 822. An abutment arm 829 extends from an end of the top arm 822 distal to the central web 814. A diagonal arm 833 extends at an acute angle from the end of the bottom arm 824 and directed back toward the central web 814. A pushing arm 835 extends from the end of the diagonal arm 833 distal to the bottom arm 824. The modified S-channel 827 is wound on the mandrel 828 with the top and bottom arms 822, 824 thereof oriented generally parallel to the outer surface 8285. Subsequent windings, e.g., 827 b overlap prior windings, e.g., 827 a with the abutment arm 829 b inserting between the junction of the diagonal arm 833 a and pushing arm 835 a and the web 814 a of the previous winding 827 a of modified S-channel. As the subsequent winding, e.g., 827 b is drawn down tightly onto the mandrel 828, the pushing arm, e.g., 835 a of the prior winding of modified S-channel, e.g., 827 a is trapped in the corner formed between abutment arm 829 b and top arm 822 b, such that the diagonal arm 833 a pushes the winding 827 b in an axial direction toward the prior winding 827 a. The top arms 822 a . . . 822 c and the bottom arms 824 a . . . 824 c, respectively, form the exterior wall surface 839 and the interior wall surface 841 of the core 826. Displacements of the core 826 in a radially compressive direction are limited by the central webs 814 a . . . 814 c, as well as by the diagonal arms 833 a . . . 833 c and the pushing arms 835 a . . . 835 c, the latter two elements having a degree of elasticity and elastic memory that may absorb energy and restore in response to compressive forces.
FIG. 18 shows an alternative embodiment of the present disclosure wherein a wall 936 of the core 926 in cross-section, has a plurality of side-by-side, overlapping modified C- channel windings 920 a, 920 b . . . 920 x. The outer arms 924 a . . . 924 x form an outer surface 938 of the wall 936 of the core 926 and the inner arms 922 a . . . 922 x form an inner surface 940 of the wall 936 of the core 926. Each of the C-channel windings 920 a . . . 920 x either overlap, are overlapped, or both, by an adjacent channel winding(s) 920 b . . . 920 x similar to the embodiment shown and described above in FIGS. 1 and 3. The outer arms 924 a . . . 924 x have an inwardly directed grip arm 925 a . . . 925 x that is received in a groove 927 a . . . 927 x on the adjacent winding, e.g., grip arm 925 b is received in groove 927 a. The angle of the grip arm 925 x relative to the outer arm 924 x may be varied. As shown by winding 920 x, the C-channel may be wound onto the mandrel 928 and positioned against an adjacent winding 920 x−1 with the outer arm 924 x displaced upwardly, out of parallel with the inner arm 922 x to facilitate adjacent positioning. The outer arm 924 x is then bent down, e.g., by a pressure roller or guide surface, such that the grip arm 925 x enters the groove 927 x−1. Alternatively, rollers and guide surfaces can be omitted if the C-channel 920 is fed onto the mandrel 828 with the arms 922 a . . . 922 x distal to the mandrel and the arms 924 a . . . 924 x proximate the mandrel, such that the arms 924 a . . . 924 x are flattened down as winding takes place. As shown in FIG. 18, the spirally wound C-channel 920 defines a continuous spiral hollow 950 which extends through the core 926. This type of hollow may be also be observed in the embodiments described above relative to FIGS. 1-17.
FIG. 19 shows a channel 1020 in accordance with an alternative embodiment of the present disclosure and having at least one opening 1081 punched therein leaving a hanging tab 1083 attached at one edge 1082. The tab 1083 may be formed in a portion 1024 of the channel 1020 that, when wound to form a spiral core, overlaps another portion 1024 a of the adjacent channel 1020 winding. As shown in FIG. 19 the other portion 1024 a which is overlapped may also have an opening 1087 or openings formed therein, such that the tab 1083 of the overlapping portion 1024 extends into the opening 1087 made in the overlapped portion 1024 a, stabilizing relative motion in the direction S between the overlapping portion 1024 and the overlapped portion 1024 a. More particularly, the periphery of the opening 1087 in the overlapped portion 1024 a will encounter the tab 1083 of the overlapping portion 1024 to limit the relative motion. This feature can be utilized in areas of overlap such as the overlap 42 shown in FIG. 5, where the upper arm 24″ and the reduced spacing portion 24 a″ can be punched to create one or more tabs 1083, 1085 and openings 1081, 1087, respectively, which can be aligned, such that the tab 1083 of the overlapping portion 24″ extends into the opening 1087 formed in the overlapped portion 24 a″. In this application, the tab 1083 will aid in preventing adjacent windings of C-channel from disassociating. The openings 1081, 1087/ tabs 1083, 1085 may be formed prior to bending or winding the C-channel, during winding, or after winding. The aligned tabs 1083 and openings 1087 may also be utilized with other of the embodiments depicted and described herein.
As described above and shown in the Figures, the term “C-channel” has been used and is intended to describe a variety of channels having a C or modified C shape. The C-shape of the above-described C-channels has a pair of arms extending from a web, with each arm having a direction of extension with a component of direction parallel to the other arm of the pair. The arms are, in this sense, “parallel.” One or both of the arms may have one or more facets or curves, such that they are not completely straight, but nevertheless can be observed to have an average or general direction. Alternatively, the arms may be straight. An aspect of the cores described above which are formed from a spirally wound C-channel with the arms extending in a direction having a component of extension in parallel with the axis of the resultant core is that the webs thereof extend outwardly from the axis of the resultant spool/core with a component of extension perpendicular to the axis. The term “radial” is therefore intended to encompass extension perpendicular to the axis or extension which has at least a component of direction perpendicular to the axis of the spool/core. Cores made from the disclosed C-channel e.g., 20, 120, 220, 320, 420, 550, 671, 770, 827, 927 provide advantages in that the outer surface of the core (that which is in contact with the wound sheet or foil product) can be manufactured with a smooth face. This smoothness prevents the loss of inner windings of product that is wrapped on the core, e.g., 26, 827, 326. The webs, e.g., 14, 114, 214 provide an “I-beam” structure, a radially oriented spiral web, making the core stronger and more rigid for a given weight. The interlocking C-channels, e.g., 20, 120, 220, 320, 927 can be wound onto the mandrel 28 with a specified axial overlapping, such that the spacing of the radial webs 14, 114, 214 and the wall 36, 136, 236 bending stiffness are easily adjusted/set for a given application. Optionally, the axial overlap of C-channels, e.g., 20, 120 could vary across the axial length of the core. This provides the option of making a portion of the core, e.g., the ends, stronger relative to the remainder, attributable to greater overlap. The cores, e.g., 26, 326, 926 have a smooth inside diameter (ID), reducing the chance that the ID of the core will be damaged by handling equipment and facilitating interaction between the core 26, 326 and handling.
Cores 26, 326 made from the disclosed C- channel 20, 120 provide a double walled thickness to the desired degree via a selective degree of overlap. Double wrapped or composite cores 426, 526, 626 and 726 provide a double thickness wall 436, 536, 636, 736 with a variety of intermediate structural features to enhance strength and rigidity. The cores 626, 726 and 826 have resilient members that impart a degree of resilience to deformation forces. The core, e.g., 26, 326, 826 may be made from recyclable material and may be formed from the same composition as the sheet product being shipped. For example, an aluminum core 26, 326, 736 may be used to hold aluminum sheet. It is possible to construct cores 26, 326, 736 using sheet metal, which for various reasons, such as width, gauge, crystallographic texture, or staining, does not meet customer specifications and which would be scrapped. Use of scrap coils provides inexpensive and readily available feedstock material for the manufacture of the winding cores 26, 326. An all- metal core 26, 326, 626, 826 e.g., an all-aluminum core, can be conveniently recycled if it is constructed of the same or similar alloy from which the sheet product is produced, e.g., unused portions of the coils of sheet product on the core 26, 326 can be recycled together with the core 26, 326.
It is understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the claimed subject matter. All such variations and modifications are intended to be included within the scope of the appended claims.

Claims

1. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:

a spirally wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool, the channel having a plurality of adjacent windings, a first of the arms of spirally wound channel cumulatively forming the outer surface and a second of the arms of spirally wound channel cumulatively forming the inner surface, the first arm and the second arm spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is receivable between the arms of adjacent windings and is retainable therein to establish an overlap of windings of the channel in the axial direction.

2. The spool of claim 1, wherein each of the first arm and the second arm has a first portion extending from the central web and a second portion extending from a free end of the arm to a transition portion extending between the first portion and the second portion, the second portion of the first arm and the second portion of the second arm having a first spacing there between approximating a second spacing between an exterior surface of the first portion of the first arm and an exterior surface of the first portion of the second arm.

3. The spool of claim 2, wherein the channel exhibits a third spacing between an exterior surface of the second portion of the first arm and an exterior surface of the second portion of the second arm and the difference between the second spacing and the third spacing approximates a radial thickness of the second portion.

4. The spool of claim 3, wherein the outer surface is cylindrical and smooth.

5. The spool of claim 1, wherein at least one of the first arm and the second arm has an undulating form in cross-section, an interior surface of the undulating form engaging and mating with an exterior surface of an undulating form of an adjacent winding of the channel of the spool.

6. The spool of claim 5, wherein both of the first arm and the second arm have an undulating form in cross-section.

7. The spool of claim 6, wherein the undulating form has first and second bulges separated by a valley, the first bulge extending from the central web.

8. The spool of claim 1, wherein the channel has at least one slot extending into the central web, the slot capable of receiving an end of at least one of the first arm and the second arm of an adjacent winding of the channel.

9. The spool of claim 8, wherein the slot is blind and is angled at an acute interior angle relative to the central web.

10. The spool of claim 9, wherein the channel has a pair of slots, a first slot disposed proximate a junction of the first arm with the central web and a second slot disposed proximate a junction of the second arm with the central web.

11. The spool of claim 10, wherein the first arm and the second arm each have an angled portion proximate a free end thereof which inserts into a corresponding one of the first slot and the second slot of an adjacent winding of the channel.

12. The spool of claim 1, wherein the channel has at least one groove in at least one of the first arm and the second arm disposed proximate the central web, and wherein at least one of the first arm and the second arm has an angled portion proximate a free end thereof which inserts into the groove of an adjacent winding of the channel.

13. The spool of claim 12, wherein the at least one groove is disposed between the central web and the first arm.

14. The spool of claim 13, wherein the at least one groove has a generally V-shaped cross-section.

15. The spool of claim 1, wherein at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.

16. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:

a spirally wound, elongated channel having an S-shaped cross-section with a pair of arms extending from a central web and having a component of extension in opposite directions, a first arm of the pair of arms having a first extension extending from an end of the first arm distal to the central web at an angle relative to the first arm and forming a top portion of the S-shape, a second arm of the pair of arms having a second extension extending from an end of the second arm distal to the central web at an angle relative to the second arm and forming a bottom portion of the S-shape, the second extension pointing towards a portion of the central web, a distal end of the second extension being distal to the second arm and spaced from the central web by a first spacing, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool, the channel having a plurality of adjacent windings, the first arm of adjacent windings of spirally wound channel cumulatively forming the outer surface and the second arm of adjacent windings of spirally wound channel cumulatively forming the inner surface, the first extension receivable between the distal end of the second extension and the central web of an adjacent winding to interlock therewith and establish an overlap in the axial direction.

17. The spool of claim 16, wherein the distal end of the second extension pushes the first extension of an adjacent winding of the channel toward the central web.

18. The spool of claim 17, further comprising a pushing arm extending from the distal end of the second extension, the pushing arm being captured in the interior angle formed between the first extension and the first arm.

19. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:

a spirally wound, elongated inner channel having a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web having a component of extension parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool, the inner channel having a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface;

a spirally wound, elongated outer channel having a second central web and a second pair of arms spaced a second distance from one another, the outer channel being oriented with the second central web generally parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool, the outer channel having a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface,

the outer channel wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.

20. The spool of claim 19, wherein the first pair of arms converge towards one another at a distal end thereof and the second pair of arms converge towards one another at a distal end thereof, the first pair of arms with the first central web forming a triangular shape and the second pair of arms with the second central web forming a triangular shape.

21. The spool of claim 20, wherein a first arm of a first adjacent winding of the outer channel and a second arm of a second adjacent winding of the outer channel are disposed within a first triangular shape of a first adjacent winding of the inner channel.

22. The spool of claim 20, wherein a plurality of adjacent windings of the inner channel each capture the first arm and the second arm of adjacent windings of the outer channel within the triangular shape, thereby interlocking the inner channel and the outer channel.

23. The spool of claim 22, wherein a plurality of adjacent windings of the outer channel each capture the first arm and the second arm of adjacent windings of the inner channel within the triangular shape, thereby interlocking the inner channel and the outer channel.

24. The spool of claim 19, wherein the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable.

25. The spool of claim 19, wherein the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.

26. The spool of claim 19, wherein the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable and wherein the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.

27. The spool of claim 26, wherein the outwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the outer channel and the inwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the inner channel.

28. The spool of claim 19, wherein at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.

29. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:

a spirally wound, elongated inner channel having a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool, the inner channel having a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface;

a spirally wound, elongated outer channel having a second central web and a second pair of arms spaced a second distance from one another, the outer channel being oriented with the second central web parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool, the outer channel having a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface,

at least one of the first arm and the second arm of at least one of the inner channel and the outer channel being scrolled inwardly toward the central web.

30. The spool of claim 29, wherein both the first arm and the second arm of at least one of the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape.

31. The spool of claim 30, wherein both the first arm and the second arm of both the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape, at least one of the inner channel and the outer channel having a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween.

32. The spool of claim 31, wherein both the inner channel and the outer channel have a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween, and wherein the outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.

33. The spool of claim 1, wherein the overlapped windings of C-channel define an internal spiral hollow extending through the spool.