Inductively coupled reels

Abstract

The reel includes a core, a first flange attached to a first end of the core, a second flange attached to the opposite second end of the core, and a first coupling joint connecting the first flange to the core. The first coupling joint 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 coupled around the first susceptor material.

Description

Technical Field

[0001] Cross - reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 503,782, filed May 23, 2023, entitled "Ferrous Induction Bonded Reel", which is hereby incorporated by reference in its entirety.

[0002]

[0002] The present disclosure generally relates to an apparatus for supporting a wound flexible medium, such as a cord, cable, fiber or wire.

Background Art

[0003]

[0003] The transportation and use of cables, wires, optical fibers and other wound media typically involve winding the flexible medium around a spool or reel. A typical reel for construction applications can have any length of lateral length (or axial height) and any flange diameter. A reel generally consists of a core around which the wound medium is wound and two flanges at both ends of the core. Such reels can be made of wood, but are often constructed from plastic and / or cardboard to obtain a better strength - to - weight ratio. Reels often further include steel bolts, staples or other connecting members. Such reels have many excellent features, but there may be difficulties in recycling due to the use of different materials. Recycling used reels is a feature that can lead to landfill reduction and overall environmental improvement.

Summary of the Invention

Problems to be Solved by the Invention

[0004]

[0004] Therefore, there is a need for a reel design that is easy to recycle while maintaining sufficient structural integrity for normal use.

Means for Solving the Problems

[0005]

[0005] This disclosure provides a design that results in a strong iron-based bonding material connection between the flange and the core. The iron-based bonding connection simplifies the manufacturing of the reel and provides an economical solution for bonding the flange to the core.

[0006]

[0006] In one embodiment of the present disclosure, the reel includes a core, a first flange attached to a first end of the core, a second flange attached to the opposite second end of the core, and a first coupling joint connecting the first flange to the core. The first coupling joint 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 coupled around the first susceptor material.

[0007]

[0007] In other embodiments, the first flange includes a core nesting region that defines an annular channel in which the first end of the core is connected to the first flange via a first coupling joint.

[0008]

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

[0009]

[0009] In some embodiments of the reel, the first susceptor material is at least partially positioned between the bottom surface of the annular channel and the first end of the core.

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

[0010]

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

[0012] The first susceptor material may further comprise a first portion positioned between the end face of the core and the bottom face of the annular channel, a second portion interposed between the inner surface of the core and the inner wall of the annular channel, and a third portion interposed between the inner surface of the core and the inner wall of the annular channel. The second portion is axially interposed between the first portion and the third portion, and the second portion has a smaller radial thickness than the third portion.

[0011]

[0013] In some embodiments, the first flange further comprises a plurality of wedge-shaped portions projecting outward from the inner wall of the annular channel, the wedge-shaped portions being configured to press the first end of the core radially outward toward the outer wall of the annular channel.

[0012]

[0014] In one embodiment of the reel, the first core material is material-bonded to the second material of the first flange in the first susceptor material.

[0015] The first susceptor material may include at least one wire arranged within an annular channel, with the first flange and the first end of the core joined together around it, and / or the first susceptor material may include a wire mesh arranged within an annular channel, with the first flange and the first end of the core joined together around it.

[0013]

[0016] The first flange can define multiple notches extending radially from the annular channel, in which the first susceptor material is partially positioned.

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

[0014]

[0018] Some embodiments of the reel include a second coupling joint connecting a second flange to a second end of a core, and further comprising a second coupling joint including a second susceptor positioned between the second flange and the second end of the core. The second flange and the second end of the core are coupled around the second susceptor material.

[0015]

[0019] The present disclosure further includes a method for manufacturing a reel, comprising the steps of interposing a first susceptor material between a first flange of the reel and a first end of a core, and exciting the first susceptor material to raise its temperature and applying a magnetic field to the first susceptor material such that it forms a first coupling joint around the first susceptor, in which the first flange is coupled to the first end of the core.

[0016]

[0020] The method may include the step of interposing a first susceptor material by inserting the first susceptor material and the first end of the core into an annular channel defined in the first flange.

[0017]

[0021] In other embodiments, the method includes the step of applying pressure to press the core and the first flange together while applying a magnetic field.

[0022] In yet another embodiment, the method includes the steps of interposing a second susceptor material between a second flange and a second opposite end of the core, and applying a magnetic field to the second susceptor material to excite it and raise its temperature, thereby forming a second coupling joint around the second susceptor material, in which the second flange is coupled to the second end of the core.

[0018]

[0023] In one embodiment, the steps of applying a magnetic field to a first susceptor material and applying a magnetic field to a second susceptor material are performed at least partially simultaneously.

[0024] Furthermore, the method may further include the step of applying axial pressure to the first and second flanges while applying a magnetic field to the first and second susceptor materials so as to press the first and second flanges toward each other. [Brief explanation of the drawing]

[0019] [Figure 1]

[0025] Front perspective view of a reel for receiving a wound medium according to the present disclosure. [Figure 2]

[0026] Exploded view of the reel of FIG. 1. [Figure 3]

[0027] Top perspective view of the core receiving region of the flange of the reel of FIG. 1. [Figure 4]

[0028] Top view of the core receiving region of the flange of FIG. 3 with a ring of bonding material disposed within the annular channel. [Figure 4A]

[0029] Top view of the core receiving region of the flange of FIG. 3 with a plurality of ring portions of bonding material disposed within the annular channel. [Figure 5]

[0030] Partial top perspective view of the core receiving region of FIG. 3 with the flange shown partially transparent to show features within the annular channel. [Figure 6]

[0031] Side cross-sectional view of the core and the core receiving region of the flange of the reel of FIG. 1 before applying a magnetic field to the bonding material. [Figure 7]

[0032] Detailed side cross-sectional view of the annular channel and the end portion of the flange of the reel of FIG. 1 after applying a magnetic field to the bonding material. [Figure 8]

[0033] Process diagram of a method for manufacturing a reel such as the reel of FIG. 1. [Figure 9]

[0034] Schematic view of a ferrous induction machine used in the method of FIG. 8. [Figure 10]

[0035] Perspective view of the ferrous induction coil of the ferrous induction machine of FIG. 9. [Figure 11]

[0036] Detailed side cross-sectional view of another bonding joint between the end portion of the core of the reel of FIG. 1 and the flange. [Figure 12]

[0037] Detailed cross-sectional view of the bonding material of the bonding joint of FIG. 11. [Figure 13]

[0038] Figure 1 is a detailed side cross-sectional view of another connecting joint between the end of the reel core and the flange. [Figure 14]

[0039] Figure 13 is a top view of the core housing area and connecting member of the connecting joint. [Figure 15]

[0040] Figure 13 is a top view of the connecting member of the connecting joint. [Figure 16]

[0041] Figure 13 is a top view of another connecting member of the connecting joint. [Figure 17]

[0042] This is a top view of the core housing area of ​​another flange of the reel in Figure 1, which has wedge-shaped ribs positioned within an annular channel. [Figure 18]

[0043] Figure 17 is a side cross-sectional view of the flange and core housing area, showing the core partially inserted into the annular channel. [Figure 19]

[0044] Figure 17 is a side cross-sectional view of the flange and core housing area, showing the forces exerted by the core and wedge-shaped ribs inserted into the annular channel. [Figure 20]

[0045] Figure 1 is a top view of the core housing area of ​​the reel, where the susceptor material is formed as two wire sections. [Figure 21]

[0046] Figure 1 is a top view of the core housing area of ​​the reel, where the susceptor material is formed as two wire mesh regions. [Modes for carrying out the invention]

[0020]

[0047] Figure 1 shows a perspective view of an exemplary embodiment of the reel 100 according to the present disclosure, and Figure 2 shows an exploded perspective view of the reel 100 of Figure 1. Referring to Figures 1 and 2, the reel 100 includes a core 104, a first flange 108, a second flange 112, a first coupling joint 116, and a second coupling joint 120. The coupling joints 116, 120 are formed by their respective coupling materials 124, 128, which are material-bonded to both the core 104 and the associated flanges 108, 112, for example, by fusion. The reel is configured such that a flexible medium, which may include a cable, wire, fiber optic cable, rope, string, etc., can be wound around the core 104 and held axially on the core by the flanges 108, 112.

[0021]

[0048] Flanges 108, 112, and connecting joints 116, 120 are substantially identical at each end of the core 104. Therefore, although the following disclosure describes only one of flanges 108 and connecting joint 116, the reader should understand that flanges 112 and connecting joint 120 at the opposite end of the core 104 may also be substantially identical.

[0022]

[0049] The core 104 is formed as a hollow cylindrical body defining the central axis 132 of the reel 100. The core 104 is formed from a plastic, which may be, for example, polypropylene plastic. In other embodiments, the core 104 is formed from polyethylene, polycarbonate, ABS, polystyrene, nylon, a combination of two or more of the above materials, or other preferred materials.

[0023]

[0050] The flanges 108 and 112 are generally disc-shaped, with an inner surface 140 (i.e., the surface facing the opposite flange) being substantially flat, and an outer surface 144 containing multiple radially and circumferentially extending structural ribs. Each of the flanges 108 and 112 has a core housing region 148. The core housing region 148 is located at the center of the flanges 108 and 112, where the flanges 108 and 112 are connected to the core 104 by their respective coupling joints 116 and 120.

[0024]

[0051] The flanges 108 and 112 are formed from a plastic such as polypropylene plastic. Alternatively, in some embodiments, the flanges 108 and 112 are formed from polyethylene, polycarbonate, ABS, polystyrene, nylon, a combination of one or more of the above materials, or other desired materials. Specifically, the flanges 108 and 112 may be formed from the same plastic material as the core 104. However, in some other embodiments, the flanges 108 and 112 and the core 104 may be formed from different plastic materials.

[0025]

[0052] Next, referring specifically to Figures 3, 6, and 7, the inner surface 140 of the core housing region 148 defines a substantially annular channel 156 centered on the central axis 132. The annular channel has substantially the same diameter as the core 104 and is formed by a substantially circular inner wall 160, a substantially circular outer wall 164, and a bottom surface 168.

[0026]

[0053] The inner wall 160 and the outer wall 164 are each angled slightly with respect to the central axis 132 such that the bottom surface of the channel 156 is narrower than the top surface of the channel 156. The angles of the inner wall 160 and the outer wall 164 may be, for example, between 0.5 and 3 degrees. In one particular embodiment, the angle formed by the inner wall 160 and the outer wall 164 with respect to the central axis 132 is about 1 degree. Furthermore, at the open end of the channel 156, the inner wall 160 and the outer wall 164 include chamfered portions 172, 176, which may be formed as a rounded edge 176 or a flat edge 172, respectively. As will be described in detail below, the angles of the inner wall 160 and the outer wall 164, as well as the chamfered edges 172, 176, facilitate the attachment of the core 104 to the annular channel 156.

[0027]

[0054] Next, referring to Figure 3, the inner wall 160 of the annular channel 156 defines a plurality of inwardly extending positioning notches 184. In the illustrated embodiment, there are three positioning notches 184, but the reader should understand that other embodiments may include any desired number of positioning notches 184. Furthermore, in the illustrated embodiment, the positioning notches 184 are defined in the inner wall 160, but the reader should understand that in other embodiments, the positioning notches 184 may be defined in the outer wall 164, or in combination with the inner wall 160 and the outer wall 164.

[0028]

[0055] Furthermore, multiple standoff tabs 188 extend upward from the base 168 and into the channel 156 from the inner wall 160 and the outer wall 164. Each standoff tab 188 extends upward from the base 168 by a distance between 0.51 and 2.5 millimeters (0.02 and 0.1 inches). In one particular embodiment, the standoff tabs 188 extend upward from the base 168 by a distance of approximately 1.3 millimeters (approximately 0.050 inches). In the illustrated embodiment, the channel 156 includes six standoff tabs (only four of which are visible in Figure 3) arranged at equal intervals around the circumference of the channel 156, with alternating inward extensions from the outer wall 164 and outward extensions from the inner wall 160. However, the reader should understand that in other embodiments, a different number of standoff tabs and / or different configurations of standoff tabs may be used.

[0029]

[0056] Figures 4 and 5 show the first bonding material 124 positioned within the annular channel 156 of the flange 108 (partially shown as transparent in Figure 5 for clarity) before the bonding process. In the illustrated embodiment, the bonding material 124 is formed as a ring 200 having a plurality of inwardly extending projections 204 corresponding to positioning notches 184 in the annular channel 156. Thus, the reader should understand that the number and shape of the projections 204 may vary depending on the configuration of the positioning notches 184. As seen in Figure 6, the ring 200 of the bonding material 124 has a substantially rectangular cross-sectional shape before the bonding process. However, in other embodiments, the shape of the ring 200 may vary as desired to orient the bonding material toward a specific location in the bonding joint 116. Furthermore, in some embodiments, the bonding material 124 is configured to form a radial interference fit in the annular channel 156. As a result, the bonding material 124 exerts a radially outward force on the walls 160 and 164 of the channel 156, thereby further facilitating bonding between the bonding material 124 and the walls 160 and 164.

[0030]

[0057] In some embodiments, the bonding material 124 may be formed as an incomplete ring, for example as a ring segment with gaps, or as a plurality of ring segments 200A (Figure 4A) defining a plurality of gaps 202 between each ring segment. In particular, using the bonding material 124 formed as one or more ring segments allows for the isolation of certain areas of the circumference of the channel 156 from the bonding material 124, thereby allowing other design features, such as radially offset holes, to exist in those areas. Furthermore, in embodiments where bonding does not necessarily need to be performed over the entire annular channel 156, the amount of bonding material 124 used may be reduced, thereby reducing the overall manufacturing cost of the reel 100.

[0031]

[0058] The binder material 124 is formed from a resin, i.e., plastic, impregnated with an iron-based susceptor material. More specifically, the plastic of the binder material 124 is compatible not only with the plastic of the core 104, particularly with the plastic of its end region if the core 104 is formed from one or more materials, but also with the plastic of the flanges 108, 112, particularly with the plastic of the annular channels 156 of the flanges 108, 112 if the flanges 108, 112 are formed from one or more materials. In one embodiment, the binder material 124 is polypropylene plastic impregnated with a susceptor material such as metal powder or metal flakes, more specifically iron powder or iron flakes. In other embodiments, the binder material 124 may be polyethylene, polycarbonate, ABS, polystyrene, nylon, or other preferred material.

[0032]

[0059] In one embodiment, the ring 200 or ring segment 200A of the bonding material 124 may be formed by injection molding, which allows the bonding material 124 to be sized and shaped to enable optimal bonding between the core 104 and the flange 108. Alternatively, in some embodiments, the bonding material 124 may be extruded directly into the annular channel 156, for example by a 3D printer or similar device, or may be formed as a cord that can be placed within the annular channel 156.

[0033]

[0060] The binder material 124 is configured such that the application of a magnetic field to the binder material 124 excites an iron-based susceptor material impregnated in the plastic. As a result, the susceptor material generates heat, which increases the temperature of the plastic in the binder material 124. This causes the plastic in the binder material 124 to liquefy and fill the volume between the end of the core 104 and the annular channel 156. A constant pressure applied to the core 104 and / or flange 108 in directions toward each other causes the end of the core 104 to displace the liquefied plastic of the binder material 124, thereby keeping the end face of the core 104 on the standoff tab 188, and further, the binder material 124 moves along at least one of the side walls of the core 104 toward the opening of the channel 156.

[0034]

[0061] In one particular embodiment, the core 104 is positioned closer to the outside 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 shorter than the distance from the inner diameter of the core 104 to the inner wall 160. When a constant pressure is applied to press the core 104 against the flange 108, the molten binder material 124 flows along the inner wall 160 of the channel 156, as the gap along the inner wall 160 is larger, while the gap between the outer wall 164 and the core 104 is smaller, so most of it remains near the base of the outer wall 164. Furthermore, the standoff tab 188 restricts the movement of the core 104 relative to the flange 108 under pressure, thereby limiting the flow of binder material out of the channel 156. As a result, any excess binder material 124 remains inside the core 104, out of sight, and does not leak out onto the outer portion of the core 104 that comes into contact with the medium wound onto the reel 100.

[0035]

[0062] The heated plastic of the binder material 124 further melts the plastic materials of the adjacent flange 108 and core 104. The molten binder material 124 mixes with the molten materials of the flange 108 and core 104, thereby causing partial mixing at the boundary between the binder material 124, the flange 108, and the core 104. When the magnetic field is deactivated, the molten binder material 124, flange material, and core material solidify, and all three materials fuse together around the susceptor material to form a bonding joint 116. Thus, the bonding joint 116 includes the material of the core 104 and the material of the flange 108, along with the iron-based impregnated susceptor and resin material of the binder material 124, which interposes between the core 104 and the flange 108 and connects them both.

[0036]

[0063] Since the materials of the flange 108 and the core 104 are fused together by the joint 116, a particularly strong bond is formed between the flange 108 and the core 104. Furthermore, the displacement of the bonding material 124 along one or more walls of the channel 156 results in the fused material being present along at least two faces of the annular channel 156 (i.e., the bottom face 168 and the inner wall 160) and at least two faces of the core 104 (i.e., its end face and its inner circumferential face), thereby further strengthening the joint 116.

[0037]

[0064] In some embodiments, the tolerance between the core 104 and the walls 160, 164 of the annular channel 156 is less than 1.6 millimeters (1 / 16 inch), more specifically less than 0.79 millimeters (1 / 32 inch), and more specifically less than 0.38 millimeters (0.015 inch). The tight tolerance reduces the amount of bonding material 124 required to manufacture the bonding joint 116, thereby reducing the overall manufacturing cost of the reel 100. Furthermore, the chamfered edges 172, 176 of the annular channel 156, coupled with the slight angles of the inner wall 160 and outer wall 164, help guide the core 104 into the annular channel 156, thus making the reel 100 easier to assemble even when the tolerance between them is tight.

[0038]

[0065] The positioning notch 184 and associated projection 204 facilitate the precise placement of the bonding material 124 within the annular channel 156. In particular, the bonding material 124, in conjunction with the positioning notch 184 and associated projection 204, may be configured differently in certain embodiments to precisely specify the position of the bonding material 124 within the annular channel 156, while also facilitating the installation of the bonding material 124 into the channel 156. Furthermore, in some embodiments, one or more of the standoff tabs 188 may be configured to form a closeout rib or wall to prevent the bonding material 124 from entering a particular portion of the channel 156.

[0039]

[0066] In one or more embodiments, the bonding material 124 may be formed integrally with either the core 104 or the flange 108 in a two-shot injection molding process. More specifically, when the flange 108 is formed as an injection-molded part, the first injection-molding shot is carried out to form the flange 108 and its associated features. In the second injection-molding shot, the bonding material 124 is formed on the bottom surface 168 and / or walls 160, 164 of the annular channel 156. Alternatively, the core 104 and its associated features are formed in the first injection-molding shot, while in the second shot, the bonding material 124 is formed on one or both ends of the core 104.

[0040]

[0067] Figure 8 shows a process diagram of method 300 for manufacturing a joint for a flexible media reel, such as the joint 116 or 120 described above. Method 300 begins with inserting the bonding material 124 into an annular channel 156 (block 310). For example, the ring 200 of the bonding material 124 is inserted into the annular channel 156 so that the projection 204 is aligned with the positioning notch 184. Alternatively, if the bonding material 124 is formed of multiple ring segments, the ring segments are inserted into the channel 156 so that the various ring segments and their associated projections are positioned in the corresponding positioning notches. In other embodiments, the binder material 124 may be injection molded into the channel 156 in a two-shot injection molding process, the binder material 124 may be inserted into the channel 156 as a cord, the binder material 124 may be directly extruded into the channel 156 using an extruder (e.g., a 3D printer), or the binder material 124 may be molded into a core 104 in a two-shot injection molding process and then inserted into the channel 156 as part of the core 104.

[0041]

[0068] Method 300 proceeds to insert the core 104 into the annular channel 156 (block 320). Specifically, the end of the core 104 is guided into the annular channel 156 by chamfered edges 172, 176 so that any slight misalignment or warping of the core 104 and / or the annular channel 156 can be easily corrected. Furthermore, the end of the core 104 is further guided to its desired position by the tapered angles of the inner wall 160 and the outer wall 164 until the core 104 rests on the bonding material 124.

[0042]

[0069] Next, pressure is applied to press the core 104 and the flange 108 together (block 330). The pressure can be applied by a hydraulic press or weight device, which is part of the iron-based induction machine 400 (Figure 9). Specifically, the machine 400 is designed to apply a constant pressure to the core 104 and the flange 108, thereby facilitating a controlled flow of the molten bonding material 124 along the inner wall 160 of the channel 156.

[0043]

[0070] Finally, method 300 in Figure 8 ends with applying a magnetic field to the binder material 124 while applying pressure (block 340). Machine 400 in Figure 9 includes one or more induction coils 420 (Figure 10) configured to generate a magnetic field when an electric current is passed through the induction coils 420. The magnetic field excites iron-based particles in the binder material 124, thereby melting the binder material 124 and the adjacent materials of the core 104 and flange 108, thereby fusing the materials of the core 104 and flange 108 with the binder material 124 to form a bonded section between the flange 108 and the core 104. Method 300 can then be repeated for the opposite end of the core 104 and the opposite flange 112.

[0044]

[0071] Readers should understand that although Method 300 is described herein in a specific order for clarity, steps 310, 320, 330, and 340 may be carried out in an order different from that described herein and shown in Figure 8. For example, applying pressure (block 330) and applying the binder material (block 340) may be carried out in reverse order, or these steps may be carried out simultaneously. Furthermore, for example, the binder material 124 and the core 104 may be inserted into the annular channel 156 simultaneously, or in the reverse order described above and shown in Figure 8 (blocks 310 and 320).

[0045]

[0072] Furthermore, in some embodiments, one or more parts of Method 300 are completed by an automated system. For example, one or more robotic components may be configured to insert the bonding material into the channel (e.g., a robotic arm positions a ring of bonding material, or a robotic extruder directly pushes the bonding material into the channel), to align and insert the core with the annular channel (e.g., using one or more robotic arms), to apply pressure to the core and flange, and / or to activate an induction coil to generate a magnetic field.

[0046]

[0073] Figures 11 and 12 show other embodiments of the coupling joint 516 that connects the core 104 and the flange 108 within the annular channel 156 of the flange 108. In the embodiments of Figures 11 and 12, the coupling material 524 is shaped like a ring, ring segment, or multiple ring segments, having the cross-sectional shape most commonly seen in Figure 12. The coupling material 524 has a base portion 532 interposed between the end of the core 104 and the bottom surface 168 of the annular channel 156, a first axial portion 536 adjacent to the base portion 532 and interposed between the inner surface of the core 104 and the inner wall 160 of the annular channel 156, and a second axial portion 540 at the outer end of the coupling material 524 having a greater radial thickness than the first axial portion 536.

[0047]

[0074] Specifically, when not installed, the second axial portion 540 has a radial thickness greater than the distance between the inner wall 160 and the inner diameter of the core 104. Therefore, when the bonding material 524 is installed in the channel 156 together with the core 104, the second radial portion 540 forms an interference fit between the inner wall 160 and the core 104, and thus the bonding material 524 exerts a radial force on both the core 104 and the inner wall 160. In some embodiments, the first radial portion 536 has a thickness that is approximately equal to or slightly greater than the distance between the inner wall 160 and the core 104, so that the first radial portion 536 fits tightly between the inner wall 160 and the core 104, or so that the first radial portion also forms an interference fit between the inner wall 160 and the core 104.

[0048]

[0075] Furthermore, the cross-section of the bonding material 524 includes two inlets 544, 548 between the base portion 532 and the first radial portion 536, and between the first radial portion 536 and the second radial portion 540. The two inlets 544, 548 are angled with respect to the axial direction 136, for example, between 20 and 40 degrees, and in one embodiment, by about 30 degrees. The inlets 544, 548 are designed to facilitate the installation of the bonding material 524 into the channel 156, despite the bonding material 524 having an inner diameter smaller than the diameter of the inner wall 160.

[0049]

[0076] The embodiments in Figures 11 and 12 can be used in the manner of Figure 8, but are further particularly advantageous for joining both flanges 108, 112 to the core 104 in a single process. Specifically, in such a configuration, the core 104 and the bonding material 524 are first placed in the annular channels 156 of both flanges 108, 112. The bonding material 524 can be fitted to both ends of the core 104 and then inserted into the annular channels 156, or the bonding material 524 can be first inserted into the annular channels 156 and then the core can be inserted into the opening in the annular channels 156 and the bonding material 524. Then, axial pressure is applied to press the flanges 108, 112 together until they are at a predetermined axial distance from each other, and then the axial pressure is reduced or terminated. A predetermined axial distance between flanges 108 and 112 can be maintained, for example, by a fixture or tool that prevents further axial movement of flanges 108 and 112 relative to each other.

[0050]

[0077] Next, a magnetic field is applied simultaneously to both ends of the reel 100 to heat the bonding material 542 in the channels 156 of both flanges 108 and 112. By radially interlocking 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 radially outward pressure on the channel 156 and the core 104, which facilitates the bonding of the bonding material 524 to the core 104 and flanges 108 during its induction heating, while reducing or eliminating the need for axial pressure that could move the flanges 108 and 112 from a predetermined distance relative to each other. As a result, both flanges 108 and 112 are bonded to the core 104 at the precise predetermined axial distance separating the flanges 108 and 112. Furthermore, since both flanges 108 and 112 can be bonded to the core 108 in a single bonding process, manufacturing time is reduced.

[0051]

[0078] Figures 13 to 15 show other embodiments of the coupling joint 616 between the core 104 and the flange 608. In the embodiments of Figures 13 to 15, a plurality of wedge-shaped notches 664 are defined in the inner wall 660 of the annular channel 656. The coupling material 624 is formed as a plurality of coupling members 628, each including a block portion 632 and a wedge portion 636. The wedge portion 636 slides into the corresponding wedge-shaped notch 664 in a radial interlocking manner, so that when the core 104 is inserted into the channel 656, the coupling member 628 exerts radial pressure on the core 104. The core 104 and the flange 608 may be coupled by axial pressure added to the radial pressure to promote a strong bond. Alternatively, as in the embodiments of Figures 11 and 12 described above, the core 104 and both flanges 608 may be bonded simultaneously without the need for axial pressure, since the bonding member 628 provides the radial pressure necessary for the bonding process. In some embodiments, the bonding member 628 is formed in part from a thermoplastic elastomer (TPE) to increase the flexural modulus of the bonding member 628 so that it can be bent for insertion into the arcuate channel 656. For example, in one embodiment, the bonding member 628 is formed from a combination of polypropylene, TPE, and iron powder.

[0052]

[0079] The coupling members 628 shown in Figures 13 to 15 can be used in reel assemblies with various core diameters and core housing shapes. Specifically, the number and position of the coupling members 628 can be selected as desired based on the diameter of the core housing and core, as well as the desired coupling strength. For example, reels with relatively small core diameters use fewer coupling members, while reels with larger core diameters use more coupling members spaced apart around the circumference of the core.

[0053]

[0080] Figure 16 shows another coupling member 728 that may be used in place of coupling member 628 in the embodiments of Figures 13 to 15. Coupling member 728 includes a plurality of block members 732, 736, and 740. The central block member 736 is connected to the wedge-shaped portion 744 as described above. Furthermore, constrictions 748 and 752 connect the block members 732, 736, and 740 together between block members 732 and 736, and between block member 736 and 740, respectively. Specifically, the constrictions 748 and 752 may be formed by relief cuts. The constrictions 748 and 752 allow the block members 732, 736, and 740 to bend relative to each other so that they can fit into the arcuate channel 656.

[0054]

[0081] Figures 17–19 show the core-receiving area 848 of another flange 808 connected to the core 104 via a coupling joint 816. The flange 808 in Figures 17–19 defines an annular channel 856 interrupted by two circular openings 858 configured to facilitate an automatic media winding machine. The annular channel 856 further includes a plurality of wedge-shaped ribs 866 positioned within the annular channel 856. Specifically, the wedge-shaped ribs 866 project from the inner surface 840 of the flange 808 toward the inner wall 860 and toward the outer wall 864 of the annular channel 856, such that the thickest radial portion of the ribs 866 is at the bottom surface 868 of the channel 856. The wedge-shaped ribs 866 are configured such that when the core 104 is inserted into the annular channel 856, the wedge-shaped ribs 866 cause an axial insertion force 870 and generate a radial outward force component 872 acting on the core 104.

[0055]

[0082] As a result, the end of the core 104 is pressed against the outer wall 864 of the annular channel 856. Therefore, if there is a gap between the core 104 and the walls 860, 864 of the annular channel 856 due to manufacturing tolerances, such a gap will be larger on the inside of the core 104 than on the outside of the core 104. Thus, once the binding material is melted and flowable within the annular channel 856, any excess binding material will flow away from the outside of the core 104 where the winding medium is located and towards the inside of the core 104.

[0056]

[0083] Furthermore, 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 outer surface of the core 104 becomes smaller. As a result, the possibility of the material to be wound being caught between the core 104 and the annular channel 856 is reduced.

[0057]

[0084] The joint 816 may include any desired number of wedge ribs 866. For example, the embodiment in Figure 17 includes 12 wedge ribs 866 arranged at equal intervals around the annular channel 856. In other embodiments, particularly those in which the bonding material is filled only in some portions of the annular channel 856, the annular channel 856 may have fewer wedge ribs 866 (see, for example, Figures 20 and 21). Specifically, in some embodiments, the wedge ribs 866 may be present only where the bonding material is inserted into the annular channel 856. Furthermore, in some embodiments, the wedge ribs 866 may be positioned at circumferential locations of other features of the flange 808, for example, at the stacking feature 876, so that the other features provide additional radial strength to the wedge ribs 866.

[0058]

[0085] Figures 20 and 21 show two additional embodiments of the bonding joints 916 and 918, where the bonding materials 924 and 926 are resin carrier-less susceptor materials inserted into the annular channel 956, respectively. Specifically, in the embodiment of Figure 20, the bonding material 924 is one or more bare ferrous wires extending along part or all of the circumferential length of the annular channel 956. In the embodiment of Figure 21, the bonding material 926 is a wire mesh, such as a ferrous wire screen, wire cloth or other flexible thin ferrous sheet material.

[0059]

[0086] The embodiments in Figures 20 and 21 are formed in essentially the same manner as described in process 300 shown in Figure 8. The bonding materials 924, 926 are inserted into the annular channel 956 until they rest on the bottom surface of the annular channel 956. The wire or mesh bonding materials 924, 926 may be inserted independently of the core 104, or they may be pushed into the annular channel 956 by the core 104 when the core 104 is inserted into the annular channel 956. In other embodiments, the bonding materials 924, 926 may be formed integrally with the flange 908 or core 104 by embedding the wire or mesh into the flange 908 or core 104 during the formation of the flange 908 or core 104, for example during its injection molding.

[0060]

[0087] After the core 104 is inserted into the annular channel 956 and pressure is applied to press the core 104 and flange 908 together, a magnetic field is applied to the bonding materials 924 and 926. The application of the magnetic field to the bonding materials 924 and 926 increases the temperature of the metal bonding material of the wire or mesh, thereby melting the material of the core 104 and the material of the flange 908 within the annular channel 956. The molten core and flange materials mix together, and when the magnetic field is removed, the core and flange materials solidify, resulting in the core 104 and flange 908 fusing together around the bonding materials 924 and 926.

[0061]

[0088] As described above, in the embodiments of Figures 20 and 21, the bonding materials 924 and 926 do not include resin bonding material. As a result, the embodiments of Figures 20 and 21 require less material for the bonding joints 916 and 918. Furthermore, the absence of resin can reduce the tolerance between the core 104 and the flange 908.

[0062]

[0089] Furthermore, in the case of the wire mesh shown in Figure 21, when inserted into the annular channel 956, the wire mesh bonding material 926 can partially enclose the end face of the core 104, thereby allowing the bonding material 926 to surround the inner and outer surfaces of the core 104. As a result, the bonding joint 918 fuses the three surfaces of the core 104 material with the flange 908 together, thereby creating a strong bond between them.

[0063]

[0090] In addition to the advantages described above, the joints 116, 120, 516, 616, 816, 916, and 918 disclosed herein offer several improvements over conventional reel assemblies. Firstly, in conventional reel assemblies, the flanges are connected to the core by bolts, which requires the use of a high-strength material, commonly paper fiber, in the core to obtain sufficient strength for the bolted connection. However, paper fibers can peel away from the core, causing damage to the flexible medium on the reel, specifically the wire or cable. Furthermore, paper fibers can cause problems with delicate equipment, especially when used in sterile environments such as server rooms.

[0064]

[0091] In contrast, the joints 116, 120, 516, 616, 816, 916, and 918 of this disclosure do not require bolts and are therefore made almost entirely from plastic, with susceptor material being the only admixture. As a result, reel 100 does not contain any paper fibers that could cause problems with the wire or other medium. Furthermore, since reel 100 is formed substantially entirely from plastic, there are no materials that could cause contamination when used in a sterile environment.

[0065]

[0092] Furthermore, since the core 104 and flanges 108, 112, 608, 808, and 908 are formed entirely from plastic, and the connecting joints 116 and 120 are formed from plastic containing only small amounts of susceptor material, such as powdered metal, mesh, or wire, the reel 100 is generally recyclable without requiring the disassembly of any of its components. Therefore,

[0093] The embodiments described above are for illustrative purposes only, and those skilled in the art can easily devise their own modifications and embodiments incorporating the principles of the present invention, which fall within the spirit and scope of the present invention.

Claims

1. The core, A first flange attached to the first end of the core, A second flange attached to the second end opposite to the aforementioned core, A first coupling joint for connecting the first flange to the core, comprising a first susceptor material disposed between the first flange and the first end of the core, and Equipped with, The first flange and the first end of the core are joined around the first susceptor material. reel.

2. The reel according to claim 1, A reel in which the first flange comprises a core housing region that defines an annular channel in which the first end of the core is connected to the first flange via a first coupling joint.

3. A reel according to claim 2, The first joint further comprises a resin material in which the first susceptor material is embedded, The resin material is material-bonded to the first material of the core and the second material of the first flange. reel.

4. A reel according to claim 2, A reel in which the first susceptor material is at least partially disposed between the bottom surface of the annular channel and the first end of the core.

5. The reel according to claim 4, A reel in which the first susceptor material is partially interposed between the inner wall of the annular channel and the radial inner surface of the core.

6. A reel according to claim 5, A reel in which the first distance between the outer wall of the annular channel and the radial outer surface of the core is smaller than the second distance between the inner wall of the annular channel and the radial inner surface of the core.

7. A reel according to claim 5, A reel comprising: a first susceptor material disposed between the end face of the core and the bottom face of the annular channel; a second portion interposed between the inner surface of the core and the inner wall of the annular channel; and a third portion interposed between the inner surface of the core and the inner wall of the annular channel, wherein the second portion is axially interposed between the first portion and the third portion, and the second portion has a smaller radial thickness than the third portion.

8. A reel according to claim 5, A reel in which the first flange further comprises a plurality of wedge-shaped portions projecting outward from the inner wall of the annular channel, wherein the wedge-shaped portions are configured to press the first end of the core radially outward toward the outer wall of the annular channel.

9. A reel according to claim 2, A reel in which the first material of the core is material-bonded to the second material of the first flange in the first susceptor material.

10. The reel according to claim 9, A reel in which the first susceptor material is disposed within the annular channel and comprises at least one wire, the first flange and the first end of the core being joined together around it.

11. The reel according to claim 9, A reel in which the first susceptor material is disposed within the annular channel and comprises a wire mesh around which the first flange and the first end of the core are joined to each other.

12. The reel according to claim 1, A reel in which the first flange extends radially from the annular channel and defines a plurality of notches in which the first susceptor material is partially disposed.

13. The reel according to claim 1, A reel in which the first flange includes a plurality of wedge-shaped notches defined in the inner wall of the annular channel, and the first susceptor material is partially disposed in the plurality of wedge-shaped notches.

14. The reel according to claim 1, A second coupling joint for connecting the second flange to the second end of the core, the second coupling joint including a second susceptor positioned between the second flange and the second end of the core. Furthermore, A reel in which the second flange and the second end of the core are joined around the second susceptor material.

15. A method for manufacturing a reel, The steps include interposing a first susceptor material between the first flange of the reel and the first end of the core, The steps include: exciting the first susceptor material to raise its temperature, and applying a magnetic field to the first susceptor material so as to form a first coupling joint around the first susceptor material in which the first flange is coupled to the first end of the core; Methods that include...

16. The method according to claim 15, A method comprising the step of interposing the first susceptor material, which includes inserting the first susceptor material and the first end of the core into an annular channel defined in the first flange.

17. The method according to claim 16, The step of applying pressure to press the core and the first flange together while the magnetic field is being applied. Methods that further include the above.

18. The method according to claim 15, The steps include interposing a second susceptor material between the second flange and the second end opposite the core, The steps include: exciting the second susceptor material to raise its temperature, and applying a magnetic field to the second susceptor material to form a second coupling joint around the second susceptor material, in which the second flange is coupled to the second end of the core; Methods that further include the above.

19. The method according to claim 18, A method wherein the steps of applying the magnetic field to the first susceptor material and applying the magnetic field to the second susceptor material are performed at least partially simultaneously.

20. The method according to claim 19, The step of applying axial pressure to the first flange and the second flange while applying the magnetic field to the first susceptor material and the second susceptor material, such that the first flange and the second flange are pressed toward each other. Methods that further include the above.

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