INDUCTION-BOUND ROLLER

Abstract

A roll comprises a core, a first flange attached to a first end of the core, a second flange attached to a second, opposite end of the core, and a first bond connecting the first flange to the core. The first bond includes a first susceptor material positioned between the first flange and the first end of the core, and the first flange and the first end of the core are arranged around the first susceptor material.

Description

Cross-reference to related applications

[0001] This application claims priority over preliminary US application No. 63 / 503,782 filed on May 23, 2023, entitled “Ferrous Induction Bonded Reel”, the disclosure of which is hereby incorporated by reference in its entirety. Field of invention

[0002] This disclosure generally relates to a device for carrying wound flexible media, e.g. cord, cable, fibers or wire. background

[0003] For the transport and use of cables, wires, optical fibers, and other wound media, the flexible media are typically wound onto a spool or reel. Typical construction reels can have any crosshead length (or axial height) and any flange diameter. Reels generally consist of a core around which the wound media is wound and two flanges at opposite ends of the core. Such reels can be made of wood but are often manufactured from plastic and / or corrugated paper for a better strength-to-weight ratio. The reels also more frequently contain steel bolts, clips, or other fasteners. Such reels have many good properties but can present recycling difficulties due to the use of different materials.Recycling used rollers can lead to a reduction in waste mountains and a general improvement in the environment.

[0004] Therefore, there is a need for a roller design that facilitates recycling while ensuring sufficient structural integrity for normal use. Summary of the invention

[0005] The disclosure provides a design that offers a strong bond of ferrous composite material between the flange and the core. This ferrous composite connection simplifies the manufacturing of the roll and provides an economical solution for joining the flanges to the core.

[0006] In one embodiment according to the disclosure, a roller comprises a core, a first flange attached to a first end of the core, a second flange attached to a second opposite end of the core, and a first bond connection connecting the first flange to the core. The first bond connection comprises a first susceptor material arranged between the first flange and the first end of the core, and the first flange and the first end of the core are connected around the first susceptor material.

[0007] In another embodiment, the first flange comprises a core nest area defining an annular channel, in which the first end of the core is connected to the first flange via the first bond connection.

[0008] In a further embodiment, the first bond connection further comprises a resin material in which the first susceptor material is embedded, and the resin material is metallurgically bonded to a first material of the core and a second material of the first flange.

[0009] In some embodiments of the roller, the first susceptor material is arranged at least partially between a base of the annular channel and the first end of the core.

[0010] In one embodiment, the first susceptor material is partially arranged between an inner wall of the annular channel and a radial inner surface of the core.

[0011] In another embodiment, a first distance between an outer wall of the annular channel and a radial outer surface of the core is less than a second distance between an inner wall of the annular channel and a radial inner surface of the core.

[0012] The first susceptor material can further comprise a first section located between an end face of the core and a base face of the annular channel, a second section located between an inner surface of the core and an inner wall of the annular channel, and a third section located between the inner surface of the core and the inner wall of the annular channel. The second section is located axially between the first and third sections, and the second section has a smaller radial thickness than the third section.

[0013] In some embodiments, the first flange further comprises a plurality of wedge-shaped sections projecting outwards from an inner wall of the annular channel, the wedge-shaped sections being configured to push the first end of the core radially outwards towards an outer wall of the annular channel.

[0014] In one embodiment of the roller, a first material of the core is metallurgically bonded to a second material of the first flange on the first susceptor material.

[0015] The first susceptor material may comprise at least one wire arranged in the annular channel around which the first flange and the first end of the core are connected, and / or the first susceptor material may comprise a wire mesh arranged in the annular channel around which the first flange and the first end of the core are connected.

[0016] The first flange can define a multitude of notches extending radially from the annular channel, in which the first susceptor material is partially arranged.

[0017] In one embodiment, the first flange comprises a plurality of wedge-shaped cutouts defined in an inner wall of the annular channel, and the first susceptor material is partially arranged in the plurality of wedge-shaped cutouts.

[0018] Some embodiments of the roll further include a second bond connection that connects the second flange to the second end of the core, wherein the second bond connection has a second susceptor material arranged between the second flange and the second end of the core. The second flange and the second end of the core are connected around the second susceptor material.

[0019] The disclosure also includes a method for manufacturing a roll, comprising arranging a first susceptor material between a first flange and a first end of a core of the roll and applying a magnetic field to the first susceptor material to excite the first susceptor material and increase the temperature of the first susceptor material, thereby forming a first bond connection around the first susceptor material to which the first flange is connected with the first end of the core.

[0020] In the process, the arrangement of the first susceptor material may include inserting the first susceptor material and the first end of the core into an annular channel defined in the first flange.

[0021] In another embodiment, the method includes applying pressure that compresses the core and the first flange while the magnetic field is applied.

[0022] In a further embodiment, the method comprises arranging a second susceptor material between the second flange and a second, opposite end of the core and applying the magnetic field to the second susceptor material to excite the second susceptor material and increase the temperature of the second susceptor material, thereby forming a second bond connection around the second susceptor material to which the second flange is connected with the second end of the core.

[0023] In one embodiment, the application of the magnetic field to the first susceptor material and the application of the magnetic field to the second susceptor material occur at least partially simultaneously.

[0024] Furthermore, the method can also include applying axial pressure to the first and second flanges during the application of the magnetic field to the first and second susceptor material in order to push the first and second flanges towards each other. Brief description of the characters Fig. Figure 1 shows a perspective front view of a reel for receiving wound media according to the revelation. Fig. 2 represents the role of Fig. 1 in an exploded view. Fig. Figure 3 illustrates a perspective top view of a core nest area of ​​a flange of the roller of Fig. 1. Fig. Figure 4 shows a top view of the core nest area of ​​the flange of Fig. 3 with a ring of connecting material arranged in an annular channel. Fig. Figure 4A illustrates a top view of the core nest area of ​​the flange of Fig. 3 with several ring-shaped sections of connecting material arranged in the ring-shaped channel. Fig. Figure 5 shows a perspective top view of a section of the core nest area of Fig. Figure 3 shows the flange partially transparent to reveal the features within the annular channel. Fig. Figure 6 is a side cross-sectional view of the core and core nest area of ​​the flange of the roller. Fig. 1 before applying a magnetic field to the binding material. Fig. Figure 7 is a detailed side cross-sectional view of the annular channel and the end of the flange of the roller. Fig. 1 after applying the magnetic field to the binding material. Fig. Figure 8 is a process diagram of a method for manufacturing a roll such as the roll of Fig. 1. Fig. Figure 9 is a schematic view of an iron induction machine used in the process according to Fig. 8 is used. Fig. Figure 10 is a perspective view of an iron induction roller of the iron induction machine by Fig. 9. Fig. Figure 11 is a detailed side cross-sectional view of another bond connection between the end of the core and the flange of the roll of Fig. 1. Fig. Figure 12 is a detailed cross-sectional view of the bonding material of the bond joint. Fig. 11. Fig. Figure 13 is a detailed lateral cross-sectional view of another bond connection between the end of the core and the flange of the roll of Fig. 1. Fig. Figure 14 is a top view of the core nest area and the connecting parts of the bond connection of Fig. 13. Fig. 15 is a top view of a connecting part of the bond connection of Fig. 13. Fig. 16 is a top view of another connecting part of the bond connection made of Fig. 13. Fig. 17 is a top view of a core nest area of ​​another flange of the roll of Fig. 1 with wedge-shaped ribs arranged in the annular channel. Fig. Figure 18 is a side cross-sectional view of the flange and the core nest area of Fig. 17, which shows that the core is partially inserted into the annular channel. Fig. Figure 19 is a side cross-sectional view of the flange and the core nest area of Fig. 17, which shows the core inserted into the annular channel and the forces exerted by the wedge-shaped ribs. Fig. 20 is a top view of the core nest area of ​​the role of Fig. 1, in which the susceptor material is formed as two wire sections. Fig. 21 is a top view of the core nest area of ​​the role of Fig. 1, in which the susceptor material is formed as two wire mesh areas. Detailed description

[0025] Fig. Figure 1 shows a perspective view of an exemplary embodiment of a roller 100 according to the disclosure, and Fig. Figure 2 shows a perspective exploded view of roll 100 from Fig. 1. Regarding the Fig. 1 and Fig. 2. The reel 100 comprises a core 104, a first flange 108, a second flange 112, a first bond connection 116, and a second bond connection 120. The bond connections 116 and 120 are formed by a corresponding bonding material 124 and 128, which is metallurgically bonded, e.g., fused, to both the core 104 and the associated flange 108 and 112. The reel is designed so that flexible media, which may include cables, wires, fiber optic cables, ropes, cords, etc., can be wound around the core 104 and held axially on the core by the flanges 108 and 112.

[0026] The flanges 108, 112 and the bond connections 116, 120 are essentially identical at each end of the core 104. The following description therefore only describes one of the flanges 108 and the bond connections 116, although the reader should understand that the flange 112 and the bond connection 120 at the other end of the core 104 may be essentially identical.

[0027] The core 104 is designed as a hollow cylindrical body that defines a central axis 132 of the roller 100. The core 104 is made of plastic, e.g., polypropylene. In other embodiments, the core 104 is made of polyethylene, polycarbonate, ABS, polystyrene, nylon, a combination of two or more of the aforementioned materials, or another desired material.

[0028] The flanges 108, 112 are generally disc-shaped, with an inner surface 140 (i.e., the side facing the opposite flange) being essentially flat and an outer surface 144 having a plurality of radially / circumferentially extending structural ribs. Each of the flanges 108, 112 has a core nest area 148 located in the center of the flange 108, 112, in which the flange 108, 112 is connected to the core 104 at the respective bond connection 116, 120.

[0029] The flanges 108, 112 are made of plastic such as polypropylene. In some embodiments, the flanges 108, 112 can also be made of polyethylene, polycarbonate, ABS, polystyrene, nylon, a combination of one or more of the aforementioned materials, or another desired material. The flanges 108, 112 can, in particular, be made of the same plastic material as the core 104. However, in some other embodiments, the flanges 108, 112 and the core 104 can also be made of a different plastic material.

[0030] Referring in particular to the Fig. 3, Fig. 6 and Fig. 7, the inner surface 140 of the core nest area 148 defines a generally annular channel 156 centered on the central axis 132. The annular channel has essentially the same diameter as the core 104 and is formed by a generally circular inner wall 160, a generally circular outer wall 164, and a base surface 168.

[0031] The inner and outer walls 160, 164 are each slightly angled relative to the central axis 132, such that the base of the channel 156 is narrower than the upper parts of the channel 156. The angles of the inner and outer walls 160, 164 can be, for example, between 0.5 degrees and 3 degrees. In a particular embodiment, the angles formed by the inner and outer walls 160, 164 relative to the central axis 132 are approximately 1 degree. Additionally, each of the inner and outer walls 160, 164 has a chamfer 172, 176 at the open end of the channel 156, which can be formed as a rounded edge 176 or as a flat edge 172. As will be explained in more detail below, the angles of the inner and outer walls 160, 164 as well as the chamfered edges 172, 176 facilitate the assembly of the core 104 into the annular channel 156.

[0032] Referring now to Fig. 3 defines the inner wall 160 of the annular channel 156 as having a plurality of inwardly extending positioning notches 184. In the illustrated embodiment, there are three positioning notches 184, although the reader should understand that other embodiments may include any desired number of positioning notches 184. Furthermore, while the positioning notches 184 are defined in the inner wall 160 in the illustrated embodiment, the reader should understand that in other embodiments the positioning notches 184 may be defined in the outer wall 164 or in a combination of the inner and outer walls 160, 164.

[0033] Furthermore, a plurality of spacer tabs 188 extend upward from the base surface 168 and into the channel 156 from the inner and outer walls 160, 164. Each of the spacer tabs 188 extends upward from the base surface 168 by a distance of between 0.02 and 0.1 inches. In a particular embodiment, the spacer tabs 188 extend upward from the base surface 168 by a distance of approximately 0.050 inches. In the illustrated embodiment, the channel 156 comprises six spacer tabs (of which in Fig. (3, only four are visible), which are evenly distributed around the circumference of the channel 156 and extend alternately from the outer wall 164 inwards and from the inner wall 160 outwards. However, it should be noted that a different number of spacer tabs and / or a different arrangement of the spacer tabs may be used in other embodiments.

[0034] The Fig. 4 and Fig. Figure 5 illustrates the first binding material 124, which is located in the annular channel 156 of the flange 108 (which is in Fig. (5, partially shown transparently for clarity) is arranged before the joining process. In the illustrated embodiment, the binding material 124 is formed as a ring 200 with a plurality of inwardly extending projections 204 that correspond to the positioning notches 184 of the annular channel 156. Thus, the reader should understand that the number and shape of the projections 204 can vary depending on the configuration of the positioning notches 184. As shown in Fig. As can be seen in Figure 6, the ring 200 made of bonding material 124 has a generally rectangular cross-sectional shape before the bonding process. However, the shape of the ring 200 can differ in other embodiments in order to direct the bonding material to specific locations of the bond joint 116. Furthermore, in some embodiments, the bonding material 124 is arranged to form a radial interference fit in the annular channel 156. As a result, the bonding material 124 exerts an outward radial force on the walls 160, 164 of the channel 156 to further facilitate the bond between the bonding material 124 and the walls 160, 164.

[0035] In some embodiments, the binding material 124 can be an incomplete ring, for example as a ring segment that includes a gap, or as a plurality of ring segments 200A ( Fig. 4A), which define a plurality of gaps 202 between the respective ring segments. In particular, the use of a binding material 124 formed as one or more ring segments makes it possible to isolate certain areas of the circumference of the channel 156 from the binding material 124, so that other design features, such as a radially offset bore, can be present in these areas. Furthermore, the amount of binding material 124 used can be reduced in embodiments in which a bond is not required around the entire annular channel 156, thereby reducing the overall manufacturing cost of the roll 100.

[0036] The binding material 124 consists of a resin, i.e., a plastic, impregnated with an iron-containing susceptor material. More precisely, the plastic of the binding material 124 is compatible with the plastics of both the core 104, particularly its end regions if the core 104 consists of more than one material, and the flanges 108, 112, particularly the annular channel 156 of the flanges 108, 112 if the flanges 108, 112 consist of more than one material. In one embodiment, the binding material 124 is a polypropylene plastic impregnated with a susceptor material such as metal powder or metal flakes, in particular iron powder / flakes. In other embodiments, the binding material 124 can consist of polyethylene, polycarbonate, ABS, polystyrene, nylon, or another desired material.

[0037] In one embodiment, the ring 200 or the ring segments 200A of the binding material 124 can be formed by injection molding, allowing the binding material 124 to be dimensioned and shaped to ensure an optimal connection between the core 104 and the flange 108. Alternatively, in some embodiments, the binding material 124 can be extruded directly into the annular channel 156, e.g., by a 3D printer or similar device, or it can be formed as a cord that can be arranged in the annular channel 156.

[0038] The binding material 124 is configured such that applying a magnetic field to it excites the iron-containing susceptor material impregnated with the plastic. This excitation causes the susceptor material to generate heat, which increases the temperature of the plastic within the binding material 124. As a result, the plastic in the binding material 124 liquefies and fills the volume between the end of the core 104 and the annular channel 156. A constant pressure applied to the core 104 and / or the flange 108 in a mutual direction causes the end of the core 104 to displace the liquefied plastic of the binding material 124, so that the end face of the core 104 rests on the spacer tabs 188, while the binding material 124 moves along at least one of the side walls of the core 104 towards the opening of the channel 156.

[0039] In a particular embodiment, the core 104 is arranged closer to the outer side of the annular channel 156, or, in other words, the distance from the outer diameter of the core 104 to the outer wall 164 is less than the distance from the inner diameter of the core 104 to the inner wall 160. When constant pressure is applied to compress the core 104 and the flange 108, the molten binder 124 flows along the inner wall 160 of the channel 156 due to the larger gap along the inner wall 160, while it remains largely near the base of the outer wall 164 due to the smaller gap between the outer wall 164 and the core 104. Furthermore, the spacer tabs 188 limit the movement of the core 104 relative to the flange 108 during pressure, thereby restricting the flow of the binder from the channel 156.As a result, excess binding material 124 remains on the inside of the core 104, so that the excess material is not visible and does not penetrate into the outer section of the core 104 that touches the media wound on the roll 100.

[0040] The heated plastic of the bonding material 124 also melts the immediately adjacent plastic material of the flange 108 and the core 104. The molten bonding material 124 mixes with the molten material of the flange 108 and the core 104, resulting in a partial mixing of the interfaces between the bonding material 124, the flange 108, and the core 104. When the magnetic field is deactivated, the molten bonding material 124, the flange material, and the core material harden, so that all three materials fuse around the susceptor material and form the bond 116. Thus, the bond 116 comprises the material of the core 104 and the material of the flange 108, with the ferrous susceptor material and the resin material of the bonding material 124 positioned between the core 104 and the flange 108, forming an interface with them.

[0041] Since the material of the flange 108 and the core 104 is fused together by the bonding compound 116, a particularly strong bond is formed between the flange 108 and the core 104. Furthermore, the displacement of the bonding material 124 along the wall or walls of the channel 156 results in the fused material being present along at least two surfaces of each of the annular channels 156 (i.e., the base 168 and the inner wall 160) and of the core 104 (i.e., at the end face and the inner circumferential surface thereof), which further strengthens the bonding compound 116.

[0042] In some embodiments, the tolerances between the core 104 and the walls 160, 164 of the annular channel 156 are 1 / 16 inch or less, particularly 1 / 32 inch or less, and especially 0.015 inch or less. These tight tolerances reduce the amount of bonding material 124 required to create the bond 116, thereby lowering the overall cost of manufacturing the roll 100. Furthermore, the chamfered edges 172, 176 of the annular channel 156, together with the slight angle of the inner and outer walls 160, 164, facilitate the insertion of the core 104 into the annular channel 156, thus simplifying the assembly of the roll 100 even with these tight tolerances.

[0043] The positioning notches 184 and the associated projections 204 facilitate the precise placement of the binding material 124 in the annular channel 156. In particular, the binding material 124, together with the positioning notches 184 and the associated projections 204, can be configured differently in certain embodiments to precisely define the positions of the binding material 124 within the annular channel 156 and simultaneously simplify its installation in the channel 156. Furthermore, in some embodiments, one or more of the spacer tabs 188 can be configured to form a finishing rib or wall to prevent the binding material 124 from penetrating certain sections of the channel 156.

[0044] In one or more embodiments, the binding material 124 can be integrally formed with either the core 104 or the flange 108 in a two-stage injection molding process. More precisely, when forming the flange 108 as an injection-molded part, a first injection molding operation is performed to form the flange 108 and its associated features. In a second injection molding operation, the binding material 124 is formed onto the base 168 and / or the walls 160, 164 of the annular channel 156. Alternatively, the core 104 and its associated features are formed in a first injection molding operation, while in a second injection molding operation, the binding material 124 is formed onto one or both ends of the core 104.

[0045] Fig. Figure 8 shows a process diagram of a method 300 for producing a bonded joint of a roll of flexible media, such as the bonded joint 116 or 120 described above. The method 300 begins with the insertion of the bonding material 124 into the annular channel 156 (block 310). For example, the ring 200 of bonding material 124 is inserted into the annular channel 156 such that the projections 204 are aligned with the positioning notches 184. Alternatively, if the bonding material 124 is formed in several ring segments, the ring segments are inserted into the channel 156 such that the different ring segments and their associated projections are arranged in the corresponding positioning notches. In other embodiments, the binding material 124 can be injected into the channel 156 in an injection molding process with two shots, the binding material 124 can be inserted into the channel 156 as a cord, the binding material 124 can be extruded (e.g.a 3D printer) directly into the channel 156, or the binding material 124 can be inserted into the channel 156 as part of the core 104 after being poured onto the core 104 in a two-shot injection molding process.

[0046] Method 300 continues with the insertion of the core 104 into the annular channel 156 (block 320). In particular, the end of the core 104 is guided into the annular channel 156 by the chamfered edges 172, 176, so that any slight misalignment or deformation of the core 104 and / or the annular channel 156 can be easily corrected. Furthermore, the end of the core 104 is guided further into its desired position by the tapered angle of the inner and outer walls 160, 164 until the core 104 rests against the binding material 124.

[0047] Pressure is then applied to press the core 104 and the flange 108 together (block 330). The pressure can be applied by a hydraulic press or a weight arrangement set up as part of the iron induction machine 400 ( Fig. 9) In particular, the machine 400 is designed to exert a constant pressure on the core 104 and the flange 108 to facilitate the controlled flow of the molten binder material 124 along the inner wall 160 of the channel 156.

[0048] Finally, the procedure 300 of Fig. 8 by applying a magnetic field to the binding material 124 (block 340) during pressure application. The machine 400 of Fig. 9 includes one or more induction coils 420 ( Fig. 10), which are configured to generate a magnetic field when an electric current is applied to the induction coils 420. The magnetic field excites the iron particles in the binder material 124 and melts the binder material 124 and the adjacent material of the core 104 and the flange 108, so that the material of the core 104 and the flange 108 fuses with the binder material 124 to form a bonded connection between the flange 108 and the core 104. The process 300 can then be repeated for the opposite end of the core 104 and the opposite flange 112.

[0049] The reader should understand that steps 310, 320, 330, and 340 are performed in a different order than described here and in Fig. The steps can be carried out in the sequence illustrated in Figure 8, although for the sake of clarity, procedure 300 is described here in a specific order. For example, the pressurization (block 330) and the application of the binding material (block 340) can be carried out in reverse order, or these steps can be carried out simultaneously. Furthermore, for example, the binding material 124 and the core 104 can be inserted into the annular channel 156 (blocks 310 and 320) simultaneously or in reverse order, as described above and in Figure 8. Fig. 8 shown.

[0050] Furthermore, in some embodiments, one or more parts of the method 300 are carried out in an automated system. For example, one or more robot components may be set up to insert the binding material into the channel (e.g., a robot arm that places the ring(s) of binding material, or a robot extruder that extrudes the binding material directly into the channel), to align the core and insert it into the annular channel (e.g., via one or more robot arms), to apply pressure to the core and the flange, and / or to activate the induction coils to generate the magnetic field.

[0051] In the Fig. 11 and Fig. Figure 12 shows another embodiment of a bond connection 516, which connects the core 104 and the flange 108 in the annular channel 156 of the flange 108. In the embodiment of Fig. 11 and Fig. 12 is the binding material 524 as a ring, ring segment or a multitude of ring segments with the in Fig. 12 most easily recognizable cross-sectional shape. The binding material 524 has a base section 532, which is arranged between the end of the core 104 and the base surface 168 of the annular channel 156, a first axial section 536, which adjoins the base section 532 and is arranged between the inner surface of the core 104 and the inner wall 160 of the annular channel 156, and a second axial section 540 at the outer end of the binding material 524, which has a greater radial thickness than the first axial section 536.

[0052] In particular, the second axial section 540, in its uninstalled state, has a radial thickness greater than the distance between the inner wall 160 and the inner diameter of the core 104. Thus, when the bonding material 524 is installed in the channel 156 with the core 104, the second radial section 540 forms an interference fit between the inner wall 160 and the core 104, so that the bonding material 524 exerts a radial force on both the core 104 and the inner wall 160. In some embodiments, the first radial section 536 has a thickness approximately equal to or slightly greater than the distance between the inner wall 160 and the core 104, so that the first radial section 536 fits tightly between the inner wall 160 and the core 104, or the first radial section also forms an interference fit between the inner wall 160 and the core 104.

[0053] Furthermore, the cross-section of the binding material 524 comprises two insertion sections 544, 548 between the base section 532 and the first radial section 536, and between the first and second radial sections 536, 540. The two insertion sections 544, 548 are angled with respect to the axial direction 136, for example, by 20 to 40 degrees, and in one embodiment by approximately 30 degrees. The insertion sections 544, 548 are designed to facilitate the installation of the binding material 524 into the channel 156, even though the binding material 524 has a smaller inner diameter than the diameter of the inner wall 160.

[0054] The embodiment of the Fig. 11 and Fig. 12 can be used for the procedure according to Fig. 8, but it is also particularly advantageous if both flanges 108, 112 are joined to the core 104 in a single operation. Specifically, in such an arrangement, the core 104 and the binding material 524 are first installed in the annular channel 156 of the two flanges 108, 112. The binding material 524 can be attached to both ends of the core 104, which is then inserted into the annular channel 156, or the binding material 524 can first be inserted into the annular channel 156 and the core then subsequently inserted into the annular channel 156 and the opening inside the binding material 524. Axial pressure is then applied to press the flanges 108, 112 together until the flanges 108, 112 have a predetermined axial distance from each other, and the axial pressure is then reduced or stopped. The specified axial distance between the flanges 108, 112 can be, for example,maintained by a device or tool that prevents further axial movement of the flanges 108, 112 relative to each other.

[0055] A magnetic field is then applied simultaneously to both ends of the roller 100 to heat the bonding materials 524 in the channels 156 of the two flanges 108, 112. Due to the radial press fit of the bonding material 524 between the inner wall 160 of the channel 156 and the inner surface of the core 104, the bonding material 524 exerts a radial outward pressure on the channel 156 and on the core 104. This facilitates the connection of the bonding material 524 to the core 104 and the flange 108 during inductive listening, while reducing or eliminating the need for axial pressure that could move the flanges 108, 112 out of the predetermined distance from each other. As a result, both flanges 108, 112 are connected to the core 104 with a precise, predetermined axial distance between the flanges 108, 112. Furthermore, both flanges 108, 112 can be joined to the core 108 in a single joining operation, which reduces the manufacturing time.

[0056] Another embodiment of a bond connection 616 between the core 104 and a flange 608 is described in the Fig. Figures 13 to 15 are shown. In the embodiment of the Fig. Figures 13 to 15 define several wedge-shaped cutouts 664 in the inner wall 660 of the annular channel 656. The binding material 624 is configured as a plurality of connecting parts 628, each comprising a block section 632 and a wedge-shaped section 636. The wedge-shaped sections 636 slide into corresponding wedge-shaped cutouts 664 with a radial interference fit, so that the connecting parts 628 exert radial pressure on the core 104 as soon as the core 104 is inserted into the channel 656. In addition to radial pressure, the core 104 and the flange 608 can also be connected with axial pressure to enable a tight connection. Alternatively, the core 104 and the two flanges 608 can be connected similarly to the embodiments described above. Fig. 11 and Fig. 12, are connected simultaneously without the need for axial pressure, since the connecting parts 628 generate the radial pressure required for the connection process. In some embodiments, the connecting part 628 is partially formed from thermoplastic elastomer (TPE) to increase its flexural elasticity, allowing it to bend for insertion into the arc-shaped channel 656. In one embodiment, for example, the connecting part 628 is formed from a combination of polypropylene, TPE, and iron powder.

[0057] The connecting parts 628 of the Fig. 13 to 15 can be used in rolls with different core diameters and core nest shapes. In particular, the number and position of the connecting parts 628 can be selected depending on the core diameter and the desired bond strength. For example, fewer connecting parts are used for rolls with relatively small core diameters, while more connecting parts are used for rolls with a larger diameter core, arranged around the circumference of the core.

[0058] Fig. 16 represents a further connecting part 728, which replaces the connecting part 628 in the embodiment of the Fig. 13-15 can be used. The connecting part 728 comprises a plurality of block elements 732, 736, 740. The central block element 736 is connected to a wedge-shaped section 744 in a manner similar to that described above. In addition, a narrowed section 748, 752 connects the block elements 732, 736, 740 to each other between each of the block elements 732, 736, 736, 740. The narrowed sections 748, 752 can be formed, in particular, by undercuts. The narrowed sections 748, 752 allow the block elements 732, 736, 740 to bend relative to each other so that the block elements 732, 736, 740 can be fitted into the arc-shaped channel 656.

[0059] The Fig. Figures 17 to 19 represent a core nest area 848 of another flange 808, which is connected to the core 104 via a bond connection 816. The flange 808 of the Fig. Figures 17 to 19 define an annular channel 856 interrupted by two circular openings 858, which are configured to facilitate an automatic winding machine for media. The annular channel 856 further comprises a plurality of wedge-shaped ribs 866 arranged within the annular channel 856. In particular, the wedge-shaped ribs 866 project from the inner wall 860 of the annular channel 856 toward the outer wall 864, beginning at the inner side 840 of the flange 808, such that the thickest radial section of the rib 866 is located at the base 868 of the channel 856. The wedge-shaped ribs 866 are arranged such that when the core 104 is inserted into the annular channel 856, the wedge-shaped ribs 866 cause the axial insertion force 870 to generate a radially outward force component 872 that acts on the core 104.

[0060] As a result, the end of the core 104 is forced against the outer wall 864 of the annular channel 856. If, due to manufacturing tolerances, a gap exists between the core 104 and the walls 860, 864 of the annular channel 856, this gap is therefore larger on the inside of the core 104 than on the outside. Thus, when the binding material is molten and fluid in the annular channel 856, any excess binding material flows to the inside of the core 104, away from the outside of the core 104 where the wound media are located.

[0061] Since the core 104 is pressed against the outer wall 864 of the annular channel 856, the gap between the annular channel 856 and the outside of the core 104 is also reduced. As a result, there is a lower risk of the wound material being trapped between the core 104 and the annular channel 856.

[0062] The bond connection 816 can have any number of wedge-shaped ribs 866. The embodiment of Fig. 17 comprises, for example, 12 wedge-shaped ribs 866 arranged uniformly around the annular channel 856. In other embodiments, particularly in embodiments where only sections of the annular channel 856 are filled with binding material, the annular channel 856 may have fewer wedge-shaped ribs 866 (see, for example, Figure 17). Fig. 20 and Fig. 21) In particular, in some embodiments, the wedge-shaped ribs 866 may be present only at the locations where the binding material is inserted into the annular channel 856. Furthermore, in some embodiments, the wedge-shaped ribs 866 may be arranged at the circumferential location of other features of the flange 808, for example, at the location of the stacking features 876, so that the other features impart additional radial strength to the wedge-shaped ribs 866.

[0063] The Fig. 20 and Fig. Figure 21 illustrates two further embodiments of bonding compounds 916, 918, in which the bonding material 924, 926 is a susceptor material that is inserted into the annular channel 956 without a resin carrier. In particular, in the embodiment of Fig. 20, the binding material 924 is one or more bare ferrous wires extending over part or all of the circumferential length of the annular channel 956. In the embodiment of Fig. 21 the binding material 926 is a wire mesh, for example an iron wire sieve, a wire mesh or another flexible thin sheet iron material.

[0064] The embodiments of Fig. 20 and Fig. 21 are produced in essentially the same way as in the one in Fig. The process is described in Figure 8, illustrated in Figure 300. The binding material 924, 926 is inserted into the annular channel 956 until it rests on the base of the annular channel 956. The wire or wire mesh binding material 924, 926 can be inserted independently of the core 104, or it can be pressed through the core 104 into the annular channel 956 when the core 104 is inserted into the annular channel 956. In another embodiment, the binding material 924, 926 can be formed integrally with the flange 908 or the core 104 during its manufacture, for example by embedding the wires or wire mesh into the flange 908 or the core 104 during injection molding.

[0065] Once the core 104 is inserted into the annular channel 956 and pressure is applied to compress the core 104 and the flange 908, the magnetic field is applied to the binding material 924, 926. The application of the magnetic field to the binding material 924, 926 causes a temperature increase in the metal of the wire or wire mesh connecting material, thereby melting the material of the core 104 and the material of the flange 908 in the annular channel 956. The molten core and flange material mix, and when the magnetic field is removed, the core and flange material solidify, so that the core 104 and the flange 908 are fused together around the binding material 924, 926.

[0066] As mentioned above, the binding material 924, 926 in the embodiment of the Fig. 20 and Fig. 21 no resin binding material. Consequently, the embodiment of Fig. 20 and Fig. 21 less material in the connection 916, 918. In addition, the tolerances between the core 104 and the flange 908 can be reduced without resin.

[0067] Furthermore, in the case of the wire mesh of Fig. 21. When inserted into the annular channel 956, the wire mesh bonding material 926 can partially wrap around the end face of the core 104, allowing the bonding material 926 to enclose sections of the inner and outer surfaces of the core 104. As a result, the bonding compound 918 fuses three sides of the material of the core 104 and the flange 908 together, creating a strong bond between them.

[0068] In addition to the advantages described above, the bond connections 116, 120, 516, 616, 816, 916, and 918 disclosed herein offer several improvements over conventional reel arrangements. First, in conventional reels, the flanges are connected to the core by screws, which necessitates the use of a high-strength material, usually paper fibers, in the core to achieve sufficient strength for the screw connection. However, the paper fibers can detach from the core and cause damage to the flexible media on the reel, particularly wires or cables. Furthermore, the paper fibers can cause problems with sensitive equipment, especially when used in sterile environments such as server rooms.

[0069] In contrast, according to the present disclosure, the bond connections 116, 120, 516, 616, 816, 916, and 918 do not require screws and can therefore be made almost entirely of plastic, with the susceptor material being the only impurity. As a result, the spool 100 contains no paper fibers that could cause problems with the wire or other media. Furthermore, since the spool 100 is essentially made entirely of plastic, there is no material that could cause contamination when used in sterile environments.

[0070] Furthermore, since the core (104) and the flanges (108, 112, 608, 808, 908) can be made entirely of plastic and the bond connections (116, 120) are made of plastic with a small proportion of susceptor material, e.g., metal powder, wire mesh or wire, the roll (100) is generally recyclable without the need to disassemble any of its components.

[0071] It is understood that the embodiments described above are merely illustrative and that skilled persons familiar with the technology can readily develop their own modifications and implementations which incorporate the principles of the present invention and fall within its spirit and scope. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 503,782

[0001]

Claims

[1] Role, comprehensive: a core; a first flange attached to a first end of the core; a second flange attached to a second, opposite end of the core; and a first bond connection connecting the first flange to the core, wherein the first bond connection comprises a first susceptor material arranged between the first flange and the first end of the core, wherein the first flange and the first end of the core are connected around the first susceptor material. [2] Roller according to claim 1, wherein the first flange has a core nest area defining an annular channel in which the first end of the core is connected to the first flange via the first bond connection. [3] Roller according to claim 2, wherein: the first bond further comprises a resin material in which the first susceptor material is embedded, and the resin material is bonded to a first material of the core and to a second material of the first flange. [4] Roller according to claim 2, wherein the first susceptor material is arranged at least partially between a base of the annular channel and the first end of the core. [5] Roller according to claim 4, wherein the first susceptor material is partially arranged between an inner wall of the annular channel and a radial inner surface of the core. [6] Roller according to claim 5, wherein a first distance between an outer wall of the annular channel and a radial outer surface of the core is less than a second distance between an inner wall of the annular channel and a radial inner surface of the core. [7] Roller according to claim 5, wherein the first susceptor material further comprises a first section arranged between an end face of the core and a base face of the annular channel, a second section arranged between an inner surface of the core and an inner wall of the annular channel, and a third section arranged between the inner surface of the core and the inner wall of the annular channel, wherein the second section is arranged axially between the first and the third section and the second section has a smaller radial thickness than the third section. [8] Roller according to claim 5, wherein the first flange further comprises a plurality of wedge-shaped sections projecting outwards from an inner wall of the annular channel, wherein the wedge-shaped sections are configured to push the first end of the core radially outwards towards an outer wall of the annular channel. [9] Roller according to claim 2, wherein a first material of the core is metallurgically bonded to a second material of the first flange on the first susceptor material. [10] Roller according to claim 9, wherein the first susceptor material comprises at least one wire arranged in the annular channel and around which the first flange and the first end of the core are connected. [11] Roller according to claim 9, wherein the first susceptor material comprises a wire mesh arranged in the annular channel and around which the first flange and the first end of the core are connected. [12] Roller according to claim 1, wherein the first flange defines a plurality of notches extending radially from the annular channel and in which the first susceptor material is partially arranged. [13] Roller according to claim 1, wherein the first flange has a plurality of wedge-shaped cutouts defined in an inner wall of the annular channel, and the first susceptor material is partially arranged in the plurality of wedge-shaped cutouts. [14] Roller according to claim 1, further comprising: a second bond connection that connects the second flange to the second end of the core, wherein the second bond connection comprises a second susceptor material arranged between the second flange and the second end of the core, wherein the second flange and the second end of the core are connected around the second susceptor material. [15] Method for manufacturing a roll, comprising: Arranging a first susceptor material between a first flange and a first end of a core of the roll; and Applying a magnetic field to the first susceptor material to excite the first susceptor material and increase the temperature of the first susceptor material, forming a first bond connection around the first susceptor material to which the first flange is connected to the first end of the core. [16] Method according to claim 15, wherein the arrangement of the first susceptor material comprises inserting the first susceptor material and the first end of the core into an annular channel defined in the first flange. [17] The method of claim 16, further comprising: Applying pressure that forces the core and the first flange together while the magnetic field is applied. [18] The method of claim 15, further comprising: Arranging a second susceptor material between the second flange and a second opposite end of the core; and Applying the magnetic field to the second susceptor material to excite the second susceptor material and increase the temperature of the second susceptor material, thereby forming a second bond connection around the second susceptor material, to which the second flange is connected with the second end of the core. [19] Method according to claim 18, wherein the application of the magnetic field to the first susceptor material and the application of the magnetic field to the second susceptor material are at least partially simultaneous. [20] The method of claim 19, further comprising: Applying axial pressure to the first and second flanges while applying the magnetic field to the first and second susceptor material in order to force the first and second flanges towards each other.

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