Reel arrangement and locking mechanism

Abstract

An apparatus and method for dispensing a wound media including one or more reels with an associated locking mechanism. The locking mechanism can allow one or more of the reels to be rotated in one particular direction, while preventing one or more of the reels from being rotated in the opposite direction.

Description

REEL ARRANGEMENT AND LOCKING MECHANISMField

[0001] This disclosure relates generally to apparatus for supporting wound flexible media, for example, cord, cable, fiber or wire.Background

[0002] The transport and use of cable, wire, optical fiber, and other wound media typically involves winding the flexible media on a spool or reel. Typical reels for construction purposes can have a traverse length (or axial height) of any length, and any flange diameter. Reels generally consist of a core around which the wound media is wrapped, and two flanges at opposite ends of the core.

[0003] Manufacturers or distributors of the wound media typically wind the media on the reels and deliver the reel with the wound media to customers. The customer then unwinds the media from the reel for the customer’s desired use. It is undesirable if the wound media becomes tangled while being unspooled, which can occur if the reel is prone to reversing or re-winding during use.

[0004] There is a need, therefore, for a reel design that simplifies unwinding of the media and reduces the propensity of the media to become tangled.Summary

[0005] Techniques are described herein that enable a method an apparatus that include a reel assembly and locking mechanism that can allow the reel to rotate in one direction and can disable rotation in the opposite direction. In some implementations, the reel assembly can include a single reel or multiple reels that can either rotate independently of one another or thatcan rotate together. The reel(s) can have a core and one or more flanges positioned on opposing ends of the reel. The flanges can have apertures that circumscribe the flange and can include a central opening that can be aligned with an outer wall of the core such that the core can pass through the central opening. Each flange can be positioned such that a portion of the core passes through the central opening and extends past the flange.

[0006] The reel assembly can include a reel stand, which can have a base and one or more end plates. Each end plate can include a cutout. The cutouts can be U-shaped and extend downwards a distance from a top edge of the end plates. The end plates can further include a locking mechanism. The locking mechanism(s) can be a plurality of protrusions that protrude from an inner face of the end plate(s). The protrusions can be radially aligned along the cutout(s) of each end plate in the same circumferential direction and can be formed as an integral portion of the material that the end plates are composed of.

[0007] In some implementations, the reel assembly can be placed into the reel stand. The portion(s) of the core that extend past the core can be positioned inside the cutout(s) in the end plates of the reel stand. The flange(s) can be positioned along the inner wall of the end plate(s). The protrusions can align with the apertures in the flanges such that the protrusions extend into at least some of the apertures. Each of the protrusions can be a flap that includes a ramp surface angled relative to the inner face of the end plate and a locking surface that is generally orthogonal to the end plate. In implementations where the protrusions are extending into at least some of the apertures, the reel can be rotated in one direction such that the ramp surface of each of the protrusions slide out of the apertures until the reel is rotated far enough that the protrusions are aligned with another set of the apertures and extend into them. When the reel is rotated the opposite direction, the locking surface braces against the aperture that the protrusion is extending into and prevents the reel from rotating.

[0008] In various implementations, the reel assembly can include multiple reels. Each adjacent reel can be joined together with a ring member that is partially nested within each adjacent reel. Each reel can be rotated independently of the other reels. The reel assembly can include multiple reel stands, each reel configured to be inserted into a respective reel stand.Alternatively, the reel assembly can include multiple intermediate disks. The intermediate disks can be a ring that is fitted around each ring member. The intermediate disks can include two sets of protrusions similar to those described with respect to the end plates. The intermediate disk protrusions can circumscribe both faces of the intermediate disk and each set can be positioned in opposing axial directions.

[0009] In some implementations, the reel assembly can be placed into a package. The package can include a window in a front face and side openings in side faces. When the reel assembly is inserted into the package, the core can be supported by the side openings of the package. A material, such as cable, wire, rope, or any other material that can be attached to the reel assembly, can be dispensed through the window.

[0010] In some implementations, the reel assembly can be mounted. The reel assembly can include an axle that has one or more endplates. Each of the endplates can be positioned at an opposing end of the axle. The endplates can include one or both of one or more mounting mechanisms, such as fastener holes, and one or more endplate protrusions.

[0011] Continuing the example from the previous paragraph, the reel assembly can include one or more reels mounted on the axle. Each of the reels can include a core portion. The core portion can be, for example, a longitudinally extending core. The axle can run through each of the core portions such that the reels become mounted on the axle.

[0012] One or more of the cores can have one or more flanges positioned at opposing ends of the core. One or more of the flanges can have one or more apertures that are radially alignedalong the flange. For example, a reel assembly can include three reels mounted on the axle. The first reel can have a flange that includes one or more apertures. The third reel can also have a flange that includes one or more apertures. These flanges can be the exterior flanges that are located most closely to the endplates, such that one or more of endplate protrusions protrude away from each respective endplate and into one or more of the apertures of the flange of the first reel and / or into one or more of the apertures of the flange of the third reel.

[0013] The first reel and the third reel can each include an additional flange. The additional flanges can be considered interior flanges, because they are positioned between the two exterior flanges. The second reel can also include two interior flanges. Each of the interior flanges can include a cutout portion and / or one or more tabs. The tab(s) and the cutout portion(s) of adjacent flanges can interact with one another such that the tabs, when aligned with the cutout portion, can extend into the cutout portion and rotationally lock the two adjacent reels together. For example, a flange of a first reel can include cutout portion that interacts with a tab that is positioned on a flange of a second reel. When the tab(s) of the second reel is protruding into the cutout of the first reel, a rotation of either the first reel or the second reel will cause a rotation of the either the second reel or the first reel, respectively. The second reel and the third reel can interact in a similar way. In some implementations, one or more of the interior flanges can have both a cutout portion and one or more tab(s), while the exterior flanges can lack both a cutout portion and one or more tab(s).Brief Description of the Drawings

[0014] FIG. 1 is a top perspective view of a packaged reel assembly.

[0015] FIG. 2 is an exploded perspective view of a packaged reel assembly.

[0016] FIG. 3 is a perspective view of a reel assembly where a reel is positioned in a reel stand.

[0017] FIG. 4 is a section view of a reel stand depicting an inside face of an end plate with a plurality of protrusions that are radially aligned along a cutout.

[0018] FIG. 5 is an exploded perspective of a packaged reel assembly that includes multiple reels and intermediate disks.

[0019] FIG. 6 is a perspective view of an intermediate disk.

[0020] FIG. 7 is an exploded perspective of a packaged reel assembly that includes multiple reels and reel stands.

[0021] FIG. 8 is a perspective view of a reel assembly that includes multiple reels and reels stands.

[0022] FIG. 9 is an exploded perspective view of a mountable reel assembly that has multiple reels.

[0023] FIG. 10 is a perspective view of a mountable reel assembly that has multiple reels.Detailed Description

[0024] FIG. 1 shows a perspective view of an exemplary embodiment of a packaged reel assembly 100. FIG. 2 shows an exploded perspective view of the packaged reel assembly 100. The packaged reel assembly 100 can include a reel assembly 104 and a package 108 in which the reel assembly is arranged.

[0025] With continuing reference to Figs. 1 and 2, the reel assembly 104 can include a reel 112 and a reel stand 116. The reel can include a core 120 and one or more flanges 124. The flanges 124 can be fixedly connected at opposing ends of the core 120. The core 120 can be any longitudinally extending member. For example, the core can be formed as a hollow cylindrical body that defines a central axis 132 of the reel 112. In some embodiments, the core 120 can be formed of corrugated material (e.g. cardboard), plywood, chipboard, wood, or paperboard. In other embodiments, the core 120 can be formed of polypropylene plastic, polyethylene,polycarbonate, ABS, polystyrene, nylon, a combination of one or more of the aforementioned materials, or another desired material. The core 120 can be formed of a single piece of material, or it can be formed of a plurality of pieces attached together to form the cylindrical core 120.

[0026] One or more of the flanges 124 can be an annular disk. The flanges 124 can include a central opening 140 and / or a one or more apertures 144. In some implementations, one or more of the apertures 144 can be radially aligned along the central opening 140. Each of the apertures 144 can be evenly spaced. The flanges 124 can be formed of corrugated material (e.g. cardboard), plywood, chipboard, wood, or paperboard. In other embodiments, the flanges 124 can be formed of polypropylene plastic, polyethylene, polycarbonate, ABS, polystyrene, nylon, a combination of one or more of the aforementioned materials, or another desired material.

[0027] The flanges 124 can be fixed to the core 120 such that the core 120 passes through the central opening 140 of the flanges 124. For example, the core 120 can extend beyond the flanges 124 by a distance that is substantially equal to or greater than the thickness of the material of the reel stand 116. In some embodiments, the core 120 cam be glued to the flanges 124, while in other embodiments the core 120 may be attached to the flanges 124 using fasteners (e.g., screws, staples, or other fasteners), a press-fit or interference-fit, or welding (e.g., via a plastic welding process such as induction welding), or fixedly connected to the flanges 124 in another suitable manner.

[0028] The reel stand 116 can include a base portion 152 and one or more end plates 156. The end plates can extend upwardly and generally orthogonally from a respective end of the base portion 152. The reel stand 116 may be formed of corrugated material. Alternatively, the reel stand 116 can be formed of another suitable material such as plywood, chipboard, wood, paperboard, metal, or plastic.

[0029] A distance between the end plates 156 of the reel stand 116 can be slightly greater than a distance between the flanges 124. The distance between the end plates 156 can be generally equal to or less than the axial length of the core 120.

[0030] One or more of the end plates 156 can include a cutout 160, where the cutout 160 can be an area of the end plates 156 that appears to be missing, or where no material is present. For example, the cutout 160 can open toward the top of the reel stand 116. The cutout 160 can be sized to accommodate the core 120 such that the core 120 can be nested inside the cutout 160. Specifically, the portions of the core 120 projecting beyond the end surface of the respective flange 124 rest on a base portion of the cutout 160 such that the cutout 160 supports the core 120 and allows the core 120 to rotate relative to the reel stand 116. In some implementations, the cutout 160 can be generally U-shaped. The cutout 160 can also include a flared portion near the top of the end plate 156. The flared portion of the cutout 160 can guide the core 120 into the cutout 160 when the core 120 is being placed into the reel stand 116. Alternatively, the cutout 160 can be oval, circular, rectangular, or any other shape necessary to accommodate the core 120.

[0031] The packaged reel assembly 100 can include a package 108 that the reel 112 and reel stand 116 can be secured inside of. The package 108 can be a standard box that has a base, front and rear walls, and two side walls. The package 108 can have substantially the same dimensions as the reel stand 116 such that the reel stand 116 can be arranged within the package 108 with little or no play. The package 108 may be, for example, a corrugated box or other suitable package. The package 108 can include a window 180 in a front or rear wall through which a wound media on the reel 112 can be unwound by a user. Additionally, in some embodiments, the package 108 can include openings 184 on each side wall to enable portions of the core 120 that extends beyond the flanges 124 to be further supported by the package 108.

[0032] In use, the reel 112 can be wound with the media and then arranged such that each end of the core 120 rests within a respective one of the cutouts 160 of the reel stand 116. The reel stand 116 can then be placed in the package 108, which can then be closed for transport to the end-user.

[0033] In FIG. 3, a perspective view of a reel 104 assembly where a reel 112 is positioned in a reel stand 116 is depicted. In FIG. 4, a section view of a reel stand 116 is depicted showing an inside face of an end plate 156 with one or more protrusions 164 that are radially aligned along a cutout 160 in the same circumferential direction. With reference to FIGS. 3 and 4, one or both of the end plates 156 of the reel stand 116 can have one or more protrusions 164 that can extend in the axially inward direction (i.e. the direction toward the associated flange 124).

[0034] One or more of the protrusions 164 can have a ramp surface 168 on one circumferential end thereof (on the end facing toward the counter-clockwise direction in the view of Fig. 4), and a locking surface 172 on the opposite circumferential end (on the end facing toward the clockwise direction in the view of Fig. 4). The locking surface 172 can be generally orthogonal to the associated end plate 156 while the ramp surface 168 can be angled relative to the associated end plate 156. The ramp surface 168 can be joined to the locking surface 172 along a top edge of the locking surface 172. In these embodiments, each of the protrusions 164 can generally form a U-shaped wedge.

[0035] The protrusions 164 can be arranged at essentially the same radius from the central axis 132 as the apertures 144 in the flanges 124 and can be spaced apart from one another the same spacing as the apertures 144. The protrusions 164 can be oriented in a particular circumferential direction relative to a center point. As a result, when the apertures 144 are aligned with the protrusions 164, the protrusions 164 can extend partially into the respectively aligned apertures 144 to limit rotation of the flanges 124 relative to the reel stand 116 in one direction, therebyforming a reel locking arrangement. In some embodiments, one or more of the protrusions 164 can be generally U-shaped.

[0036] In some implementations, the protrusions 164 are integral members of the end plate 156. The protrusions 164 may be formed, for example, by a die cutting process in which the shape of the protrusions 164 is cut through the material of the end plate 156 and the resulting flap is pressed from the opposite side of the material such that the flap projects from the axially inward side of the end piece 156. In other embodiments, the protrusions 164 may be formed by stamping, thermoforming, vacuum forming, pressure molding, injection molding, embossing, or another desired process. Alternatively, the protrusions 164 can be individual pieces that are attached to the end plate 156.

[0037] To use the packaged reel assembly 100 as depicted in FIG. 1, the user can feed one end of a media that is wound around the core 120 through the window 180 in the package 108. The media can then be pulled through the window 180, which can cause the reel 112 to rotate within the package 108 and, more specifically, the core 120 to rotate within its support in the cutouts 160. As the reel 112 rotates in the unwinding direction (i.e., clockwise as viewed from the right in Fig. 3), the edges of the aperturesl44 in the flanges 124 can slide along the ramp surfaces 168 of the protrusions 164 and allow for the rotation of the flanges 124.

[0038] Once the user stops pulling the media through the window 180, the reel 112 can cease to rotate relative to the reel stand 116 due, in part, to the friction between the protrusions 164 and the flanges 124 and, potentially, the engagement between the ramp surfaces 168 and the edges of the apertures 144 in the end plates 156 of the reel stand 116. The protrusions 164 can snap into corresponding apertures 144 as the reel 112 ceases to rotate. If rotational force is applied to the reel 112 in the reverse direction, or in other words in the winding direction (i.e., counterclockwise as viewed from the right in Fig. 3), the locking surfaces 172 of the protrusions164 can engage with the edges forming the apertures 144. As a result, the locking arrangement can prevent the reel 112 from rotating in the winding direction, which avoids tangling of the wound media in the packaged reel assembly 100.

[0039] Figs. 5A-B and 6A-B illustrate a second embodiment of a packaged reel assembly 200A that is similar to the packaged reel assembly 100 of the embodiment of Figs. 1-4, but in which the reel assembly 204 includes plurality of reel portions 212A-C. Each reel portion 212A- C can include a core portion 220A-C and one or more flanges 224A-C, 226A-C, each of which can be fixedly connected to a respective end of its associated core portion 220A-C. For example, each core portion 220A-C can include a respective pair of flanges 224A-C, 226A-C, such as core portion 220A having flanges 224A and 226A. Each of the core portions 220A-C can be configured substantially the same as the core 120 discussed above, except that only the outermost end portions of the core portions 220A, 220C can extend beyond the outer surface of the outermost flanges 224A, 226C, respectively, to mount in the cutout 160.

[0040] The reel assembly 204 can further include one or more reel interfaces 228A and 228B. Each respective reel interface 228A and 228B can be arranged between each adjacent pairs of reel portions 212A-B and 212B-C. Each reel interface 228A-B can include an intermediate disk 232A-B and a ring member 236A-B. The ring members 236A-B can each be partially nested within each of the two adjacent core sections 220A-B and 220B-C such that the middle core portion 220B is supported by the two outer core portions 220A, 220C while being rotatable relative to the outer core portions 220A, 220C. For example, the ring members 236A-B can be cylindrical and have a diameter that is slightly less than the diameter of the core sections 220A- C, such that the ring members 236A-B can be positioned inside of the core sections 220A-C with a tight fit. The intermediate disks 232A-B can be interposed between and in contact with the two adjacent flanges 226A, 224B and 226B, 228A, respectively. In some embodiments, theintermediate disks 232A-B can be fixedly connected to the reel stand 116 such that the intermediate disks 232A-B do not rotate.

[0041] In various embodiments, the reel assembly 204 can include three reel portions 212A-C. However, the reel assembly 204 can alternatively include any two of the reel potions 212A-C. For example, the reel assembly 204 can include only portions 212A-B, 212B-C, or 212A and C. In these embodiments, any of the joined reel portions 212A-C still include the general structure described above. In other embodiments, the reel assembly 204 may include reel portions and accompanying structure in addition to reel portions 212A-C.

[0042] The intermediate disks 232A-B are illustrated in more detail in Fig. 6. Similar to the end plates 156 of the reel stand 116, each intermediate disk 232A-B can include one or more protrusions 244, 248 spaced around the circumference of the disks 232A-B. The protrusions 244, 248 can be evenly spaced. The protrusions 244, 248 of the intermediate disks 232A-B can altematingly project in opposite axial directions such that the protrusions 244 project from a first side of the disk 232A-B (e.g., to the left in Fig. 6), while the protrusions 248 project from the opposite side of the disk 232A-B (e.g., to the right in Fig. 6). Thus, for example, the protrusions 244 of the intermediate disk 232A can engage with the apertures 144 of the adjacent flange 226A of the end reel portion 212A, while the protrusions 248 on the opposite side of the intermediate disk 232A can engage with the apertures 144 of the flange 224B of the middle reel portion 212B. Additionally, each of the protrusions 244, 248 can be oriented in the same circumferential direction as the protrusions 164 such that the ramp surfaces and locking surfaces of the protrusions 244, 248, and the protrusions 164 are all aligned with one another.

[0043] The protrusions 244 and 248 can be formed in the same ways as the protrusions 164 as described with respect to FIG. 4. In some implementations, the protrusions 244 and 248 can beintegral members of each of the respective intermediate disks 232A-B. Alternatively, they can be separate members that are attached to the intermediate disks 232A-B.

[0044] As a result, when media on the reel portion 212A is pulled in the unwinding direction, the apertures 144 in the outer flange 224 A can rotate relative to the protrusions 164 of the end plate 156 of the reel stand 116 in a manner similar to the embodiment of Figs. 1-4. The apertures 144 in the inner flange 226A can also rotate relative to the intermediate disk 232A, thereby allowing the intermediate disk 232A to remain in a fixed rotational position relative to the reel portion 212A. As a result, the reel portion 212A can unwind without also unwinding the reel portion 212B. When force is applied to the reel portion 212A in the winding direction, the apertures 144 on the outer flange 224A can engage with the locking surfaces 172 of the protrusions 164 in the reel stand 116, thereby preventing rotation of the reel portion 212A in the winding direction. The reel portion 212C operates in a similar manner as the reel portion 212A.

[0045] When the media on the reel portion 212B is unwound, the apertures 144 on both flanges 224B, 226B can move along the ramp surfaces of the protrusions 248, 244 of the respectively adjacent intermediate disk 232A, B, thereby allowing the flanges 224B, 226B to move relative to the intermediate disks 232A, B. As a result, the reel portion 212B can be unwound without also unwinding the reel portions 212A or 212C.

[0046] When force is applied to the reel portion 212B in the winding direction, the apertures 144 of the flanges 224B, 226B can engage with the locking surfaces 172 of the protrusions 248, 244 of the adjacent intermediate disks 232A, B. The protrusions 244, 248 on the opposite sides of the intermediate disks 232A and 232B can then engage with the apertures 144 of the associated flanges 226A, 224B and 226B, 224C, respectively, which apply the rotational force in the winding direction to the end reels 212A, 212C. The end flanges 224A, 226C, however, can be locked from rotation in the winding direction by the locking surfaces 172 of the protrusions164 of the reel stand 116. Consequently, since the reel portion 212B is rotationally fixed relative to the end reel portions 212A, C, and the end reel portions 212A, C are rotationally fixed relative to the reel stand 116, the middle reel portion 212 can be prevented from rotating in the winding direction.

[0047] Accordingly, in the embodiment of Figs. 5 and 6, the reel portions 212A-C can be unwound independently of one another. However, the reel portions 212A-C lock to one another in the winding direction and are prevented from rotating in the winding direction. Thus, the media on the reels 212A-C is less likely to become tangled.

[0048] Alternatively, in a variation of the embodiment of Figs. 5 and 6, the intermediate disks can be replaced with intermediate pieces of the reel stand 116. The intermediate pieces can be shaped similarly to the end pieces 156, but configured with alternating protrusions similar to the protrusions 244, 248 of the intermediate disks. The intermediate pieces can be fixedly connected to the base portion 152 and project upwardly with a cutout that receives one end of each adjacent reel portion 212A-C. As a result, the reel portions 212A and 212C can be mounted in one intermediate piece and one end piece 156, while the reel portion 212B can be mounted in two intermediate pieces. In this variation, each reel portion 212A-C can be unwound independently of the other reel portions 212A-C, but can be prevented from rotating in the winding direction, in a similar manner as the reel 120 of the embodiment of Figs. 1-4.

[0049] Figs. 7 and 8 illustrate another embodiment of a packaged reel assembly 200A that is similar to the embodiment of Figs. 5 and 6. The embodiment of Figs. 7 and 8, however, includes three reel stands 116A-C, each of which can include a base portion 152 and two end pieces 156 that include a cutout 160. The cutout(s) 160 can be generally U-shaped. In particular, each of the reel stands 116A-C is configured similarly to the reel stand 116 described above. In some embodiments, that the base portion 152 can be shorter along the longitudinal direction of the reelassembly such that only one of the reel portions 212A-C is accommodated between the end pieces 156 of each respective reel stand 116A-C.

[0050] The reel assembly 204A of Figs. 7 and 8 is similar to the reel assembly 204, except that no intermediate disks are present. In some implementations, one or more additional ring members 236C, 236D can be included, with one at the outer end of one ore more of the outer reels 212A and 212C, such that one or more of the additional ring member(s) 236C and 236D can be partially nested within one of the cylindrical cores 212A-C. For example, the outer ring members 236C and 236D can be fitted within the associated reel portion 212A and 212C, respectively, and serve to support the reel portions 212A, 212C in the cutout 160 of the associated reel stand 116A and 116C and / or in the openings 184 of the package 108. Alternatively, the reel portions 212A-C can have a portion that extends through each of the flanges. That portion can be supported by the associated reel stand 116A-C.

[0051] In the embodiment of Figs. 7 and 8, one or more reel portions 212A-C can be mounted in an associated one of the reel stands 116A-C. The reel portions 212A-C therefore can interact with the associated reel stand 116A-C in a manner similar to the reel 112 of the embodiment of Figs. 1-4. Specifically, each reel portion 212A-C can rotate relative to the associated reel stand 116A-C in the unwinding direction due to the ramp surfaces 168. However, the locking surfaces 172 can interact with the apertures 144 of each reel portion 212A-C to prevent the reel portions 212A-C from rotating in the winding direction. As a result, each of the reel portions 212A-C can be rotatable independently of one another in the unwinding direction, and each reel can be disabled from rotation in the winding direction.

[0052] Figs. 9 and 10 depict another embodiment of a reel assembly 300 having one or more reel portions 304A-C, and in which the reel assembly is configured to be mounted. The reel assembly 300 can include two end plates 308 that are fixedly connected to one another by anaxle 312. Each of the end plates 308 can include at least one mounting mechanism 316, such as a fastener hole. Each of the endplates 308 can include multiple mounting mechanisms 316. For example, the endplates 308 can include three fastener holes. The mounting mechanism 316 can enable the reel assembly 300 to be hung with a hook or other fastening mechanism on a stand, rack, or other suitable mounting structure. Each of the end plates 308 can also include a plurality of protrusions 318 radially aligned around the end plate 308 and configured the same as the protrusions 164 described above.

[0053] Each of the one or more reel portions 304A-C can include one or more flanges 320A- B, 324A-B, 328A-B, respectively, and a core portion 332, 336, 340, such as a longitudinally extending cylindrical core. The core portions 332, 336, 340 can be supported on the axle 312 such that they are rotatable about the axle 312. For example, the axle 312 can be inserted through each of the core portions 332, 336, 340, such that the reels 304A-C can be rotated about the axle 312.

[0054] Each pair of flanges 320A-B, 324A-B, 328A-B can be fixedly connected to the respective core portion 332, 336, 340. Each respective flange of each pair of flanges 320A-B, 324A-B, 328A-B can be positioned at opposing ends of the respective core portion 332, 336, 340. For example, flange 320A can be positioned at a first end of core portion 332, while flange 320B can be positioned at a second end of core portion 332. Additionally and / or alternatively, one or more of the flanges 320A-B, 324A-B, 328A-B can include one or more apertures 344. For example, flanges 320A, 328B, which are exterior flanges positioned closest to the endplates 308, can include a plurality of apertures 344. The apertures 344 can be radially aligned around a central flange opening and / or can be spaced around the circumference of the flanges 320A-B, 324A-B, 328A-B. The spacing of the apertures 344 can be similar to the spacing of the protrusions 318 of the end plates 308. In some embodiments, all of the flanges 320A-328B caninclude the apertures 344. In some implementations, one or more of the flanges 320A-B, 324A- B, 328A-B may not include the apertures in some embodiments. For example, flanges 320B, 324A-B, 328A, which are interior flanges that are not nearest to the endplates 308A may not include the apertures 344.

[0055] One or more of the flanges 320A-B, 324A-B, 328A-B can include one or more cutouts 348 and / or one or more tabs 352. For example, each of the interior flanges 320B-328A can include a cutout 348 and a pair tabs 352. The tab(s) 352 of a respective flange 320A-B, 324A-B, 328A-B can align with the cutout 348 of an adjacent flange 320A-B, 324A-B, 328A-B. The tab(s) 325 of a particular flange 320A-B, 324A-B, 328A-B, when aligned with the cutout 348 of an adjacent flange 320A-B, 324A-B, 328A-B, can extend into the cutout 348 and rotationally lock two of the reel portions 304A-C together. For example, a pair of tabs 352 on flange 324B can align with a cutout 348 of flange 328A to rotationally lock reel portions 304B and 304C together. In some implementations, one or more of the flanges 320A-B, 324A-B, 328A-B can include both a cutout 348 and one or more tabs 352. For example, flange 324B can include a pair of tabs 352 and a cutout 348. In these implementations, an adjacent flange 320A-B, 324A- B, 328A-B, for example flange 328A, can also include a cutout 348 and a pair of tabs 352. In this way, the tabs of flange 324B can align with the cutout 348 of flange 328A and vice versa. This alignment can occur simultaneously or at different times to provide another rotationally locked position for one or more of the reels 304A-C.

[0056] For example, when the tabs 352 of the flanges 320B, 324A are inserted into the associated cutouts 348, the middle reel portion 304B can be locked for rotation with the outer reel portion 304A. Likewise, when the tabs 352 of the flanges 324B, 328A are inserted into the associated cutouts 348, the middle reel portion 304B can be locked for rotation with the outer reel portion 304C. As a result, the user can selectively configure the reels such that the middlereel portion 304B rotates independently of the outer reel portions 304A, 304C, or that the middle reel portion 304B rotates together with the outer reel portion 304 A or with the outer reel portion 304C. Alternatively, the user may join all three reel portions 304A-C together using the tabs 352 and cutouts 348 such that the media on all three reel portions 304A-C can be unwound together.

[0057] The cutout(s) 348 can be a variety of shapes. For example, the cutout(s) can be rectangular, circular, triangular, or any other functional shapes that facilitates the functions described herein. The tab(s) 352 can also and / or alternatively be a variety of shapes as well. For example, they can have cross section that is triangular, rectangular, trapezoidal, circular, cylindrical, or any other functional shapes that facilitates the functions described herein. The tab(s) 352 can be integral with the flanges 320A-B, 324A-B, 328A-B. For example, the tab(s) 352 can be a flap that is cut from the flange 320A-B, 324A-B, 328A-B, itself. Alternatively, the tab(s) 352 can be an additional piece that is attached to the flanges 320A-B, 324A-B, 328A-B. The tabs(s) can be formed in the same way as the protrusions described above with respect to FIGS. 1-8.

[0058] In some embodiments, the protrusions 318 of the end plates 308 and the apertures 344 of one or more of the flanges 320A-B, 324A-B, 328A-B, for example the outer flanges 320A, 328B, can engage in a similar manner as in the embodiments described above. Thus, the one or more of the reel portions 304A-C, such as the outer reel portions 304A, 304C can rotate in the unwinding direction, and can be disabled from rotating in the winding direction.

[0059] Additionally or alternatively, in some implementations, an intermediate disk such as the intermediate disk 232 of Figs. 5 and 6 can be interposed between the flanges of adjacent reel portions 304A-C. In particular, the intermediate disks can be fixed to the axle 312 such that the intermediate disks are fixed relative to the end plates 308. Accordingly, in such a configuration, the reel portions 304A-C operate in a similar manner as in the implementation of FIGS. 5 and 6such that the media on each reel portion 304A-C can be unwound independently of the other reel portions 304A-C, but none of the reel portions 304A-C may be rotated in the winding direction.

[0060] It will be appreciated that the above-described implementations are merely illustrative, and that those of ordinary skill in the art may readily devise their own modifications and implementations that incorporate the principles of the present invention and fall within the spirit and scope thereof.

Claims

ClaimsWhat is claimed is:

1. A reel assembly comprising: a reel stand having a base and two end plates that extend upwards from opposing ends of the base, wherein each of the end plates includes a cutout that extends downwards from a top edge of each of the end plate and a plurality of protrusions radially aligned along at least a portion of the cutout on an inside face of each of the end plates; and a reel having a longitudinally extending core and at least two flanges positioned at opposing ends of the core, each flange having a central opening and a plurality of apertures that circumscribe the central opening, wherein each flange has a respective portion of the core that extends through the central opening into a respective one of the cutouts of the end plates and wherein the plurality of protrusions extend into at least some of the plurality of apertures.

2. The reel assembly of claim 1, wherein each of the cutouts is U-shaped.

3. The reel assembly of claim 1, wherein each of the plurality of protrusions is a flap that is angled relative to a plane of the associated end plate.

4. The reel assembly of claim 3, wherein the flap includes a ramp surface and a locking surface, wherein the locking surface is generally orthogonal to the associated end plate and the ramp surface is angled relative to the associated end plate along a top edge of the locking surface.

5. The reel assembly of claim 1, further comprising a package having two side walls, front and rear walls that extend upwards from the base, a window in the front wall and two side wall apertures, wherein the reel stand and reel are positioned inside the package.

6. The reel assembly of claim 5, wherein the each respective portion of the core that extends into the respective one of the cutouts further extends into a respective one of the side wall apertures.

7. The reel assembly of claim 1, wherein the reel assembly is composed of a corrugated material.

8. A reel assembly locking mechanism comprising: a plurality of apertures circumscribing a flange positioned at an end of a reel that is mounted in a reel stand; a plurality of protrusions that extend outwards from an inner face of an end plate that extends upwards from a base of the reel stand, each protrusion of the plurality of protrusions being a flap having a locking surface that extends generally orthogonally to the inner face of the end plate and a ramp surface that is angled relative to the inner face of the end plate and extends along a top edge of the orthogonal surface; and each of the protrusion of the plurality the plurality of protrusions being oriented in a particular circumferential direction and aligning with and extending into at least a subset of the plurality of apertures.

9. The reel assembly locking mechanism of claim 1, wherein the plurality of protrusions are radially aligned along a cutout in the end plate of the reel stand.

10. The reel assembly locking mechanism of claim 1, wherein each of the protrusions is U- shaped.

11. The reel assembly locking mechanism of claim 1, wherein the plurality of protrusions are integral with the end plate.

12. A reel assembly comprising:a reel stand having a base and one or more endplates, wherein one or more of the endplates extend generally orthogonally from the base, wherein the one or more end plates include a cutout and wherein one or more of the endplates include one or more protrusions that are radially aligned along at least a portion of the cutout of one or more of the endplates; and a reel having a longitudinally extending core and one or more flanges that each include a central opening, wherein each flange, of the one or more flanges, is positioned at either a first end of the longitudinally extending core or a second end of the longitudinally extending core, wherein one or more of the flanges includes one or more apertures that are radially aligned along at least a portion of the central opening of one or more of the flanges, wherein one or more of the protrusions of one or more of the endplates extend one or more of the apertures, and wherein one or both of the first end of the longitudinally extending core and the second end of the longitudinally extending core extend into the cutout of the one or more of endplates.

13. The reel assembly of claim 12, wherein each of the cutouts of the one or more endplates is U-shaped.

14. The reel assembly of claim 12, wherein one or more of the protrusions is a flap.

15. The reel assembly of claim 14, wherein the flap includes a ramp surface and a locking surface, wherein the locking surface is generally orthogonal to one or more of the end plates and the ramp surface is angled relative to one or more of the end plates.

16. The reel assembly of claim 12, further comprising a box having a window in a front wall and one or more side wall apertures in one or more side walls, wherein the reel stand and reel are positioned inside the box.

17. The reel assembly of claim 16, wherein one or both of the first end of the longitudinally extending core and the second end of the longitudinally extending core further extend into one or more of the side wall apertures in one or more of the side walls.

18. The reel assembly of claim 12, wherein the reel assembly is composed of a corrugated material.

19. A reel assembly comprising: a reel stand having a base and two end plates that extend upwards from opposing ends of the base, wherein each of the end plates includes an inside face, an outside face, a cutout that extends downwards from a top edge of each of the end plate and a plurality of end plate protrusions radially aligned along at least a portion of the cutout on the inside face of each end plate; a plurality of reels including two outer reels and at least one inner reel positioned in between the two outer reels, each reel having a longitudinally extending cylindrical core, the two outer reels having an inner flange and an outer flange, the inner reel having two inner flanges, wherein each flange is positioned at opposing ends of a respective one of the cylindrical cores and has a central flange opening that at least a portion of the respective one of the cylindrical cores extends through and a plurality of apertures that circumscribe the central flange opening, wherein each portion of the cylindrical cores that extends through one of the outer flanges is positioned inside one of the cutouts of one of the end plates and each set of the plurality of end plate protrusions extend into one or more of the plurality of apertures of each of the outer flanges ; at least two reel interfaces joining each of the two outer reels to the inner reel, wherein each of the reel interfaces include:a cylindrical ring member that has a diameter slightly less than a diameter of each of the cylindrical cores and is partially nested into the cylindrical cores of one of the outer reels and the inner reel; and an intermediate disk having an inner face and an outer face, a central intermediate disk opening that fits around the cylindrical ring member, a plurality of inner face protrusions that extend from the inner face and a plurality of outer face protrusions that extend from the outer face, wherein the inner face protrusions and the outer face protrusions circumscribe the central intermediate disk opening, the inner face protrusions extending into the plurality of apertures of one of the inner flanges of the inner reel and the outer face protrusions extending into the plurality of apertures of the inner flange of one of the outer reels.

20. The reel assembly of claim 19, wherein each of the cutouts is U-shaped.

21. The reel assembly of claim 19, wherein each of the plurality of end plate protrusions, inner face protrusions, and outer face protrusions is a flap and wherein the end plate protrusions are angled relative to a plane of the associated end plate and the inner face protrusions and outer face protrusions are angled relative to the associated intermediate disk.

22. The reel assembly of claim 21, wherein each of the flaps includes a ramp surface and a locking surface, wherein the locking surface of the is generally orthogonal to the associated end plate or intermediate disk and the ramp surface is angled relative to the associated end plate or intermediate disk along a top edge of the locking surface.

23. The reel assembly of claim 19, further comprising a package having two side walls, front and rear walls that extend upwards from the base, a window in the front wall and two side wall apertures, wherein the reel stand and reels are positioned inside the package.

24. The reel assembly of claim 23, wherein each portion of the cylindrical cores that extends through one of the outer flanges further extends into a respective one of the side wall apertures.

25. The reel assembly of claim 19, wherein the reel assembly is composed of a corrugated material.

26. A reel assembly locking mechanism comprising: a first outer flange and a second outer flange, each having one or more outer flange apertures radially aligned along an outer flange central opening, wherein the first outer flange is positioned at a first end of a reel assembly and the second outer flange is positioned at a second end of the reel assembly, and wherein the reel assembly is mounted in a reel stand; one or more reel stand protrusions that extend outwards from the reel stand, wherein one or more of the reel stand protrusions extend into one or more of the outer flange apertures of the first outer flange and one or more of the reel stand protrusions extend into one or more of the outer flange apertures of the second outer flange; a first inner flange and a second inner flange, each having one or more inner flange apertures radially aligned along a central inner flange opening, wherein the first inner flange and the second inner flange are each positioned between the fist outer flange and the second outer flange on the reel assembly; and an intermediate disk positioned between the first inner flange and the second inner flange, wherein the intermediate disk includes one or more first intermediate disk protrusionsand one or more second intermediate disk protrusions, wherein the one or more first intermediate disk protrusions and the one or more second intermediate disk protrusions are radially aligned along a central intermediate disk opening, and wherein the first intermediate disk protrusions extend into one or more of the inner flange aperture of the first inner flange and the second intermediate disk protrusions extend into one or more of the inner flange apertures of the second inner flange.

27. The reel assembly locking mechanism of claim 26, wherein one or more of the reels stand protrusions are radially aligned along a cutout in the reel stand.

28. The reel assembly locking mechanism of claim 26, wherein one or more of the reel stand- protrusions are U-shaped.

29. The reel assembly locking mechanism of claim 28, wherein one or more of the reel stand protrusions are flaps having a locking surface that extends generally orthogonally to the reel stand and a ramp surface that is angled relative to the reel stand.

30. The reel assembly locking mechanism of claim 29, wherein one or more of the reel stand protrusions are integral with the reel stand.

31. The reel assembly locking mechanism of claim 26, wherein one or more of the intermediate disk protrusions are U-shaped.

32. The reel assembly locking mechanism of claim 31, wherein one or more of the first intermediate disk protrusions and one or more of the second intermediate disk protrusions are flaps having a locking surface that extends generally orthogonally to the intermediate disk and a ramp surface that is angled relative to the intermediate disk.

33. The reel assembly locking mechanism of claim 26, wherein one or more of the first intermediate disk protrusions and one or more of the second intermediate disk protrusions are integral with the intermediate disk.

34. A reel assembly comprising: a reel stand having a base and one or more endplates, wherein the one or more endplates extend generally orthogonally from the base, wherein the one or more end plates include a cutout and wherein the one or more endplates each include one or more end plate protrusions that are radially aligned along at least a portion of the cutout of the one or more endplates; a plurality of reels, each having a longitudinally extending cylindrical core and a pair of flanges positioned at opposing ends of the longitudinally extending cylindrical core, wherein each of the flanges have one or more apertures radially aligned around a flange central opening, wherein the one or more endplate protrusions protrude into one or more of the apertures, and wherein the longitudinally extending cylindrical core of one or more of the plurality of reels extends into the cutout of one or more of the endplates; one or more reel interfaces, each including a cylindrical ring member that is partially nested inside of the longitudinally extending cylindrical core of each of a pair of reels of the plurality of reels and an intermediate disk positioned around the cylindrical ring, wherein the intermediate disk of each of the one or more reel interfaces includes a plurality of intermediate disk protrusions, wherein the plurality of intermediate disk protrusions include a first subset of intermediate disk protrusions and a second subset of intermediate disk protrusions, and wherein the first subset of intermediate disk protrusions and the second subset of intermediate disk protrusions protrude from opposite faces of the intermediate disk and into one or more of the apertures.

35. The reel assembly of claim 34, wherein the plurality of reels includes a pair of outer reels and an inner reel.

36. The reel assembly of claim 34, wherein the cutouts in the one or more of the endplates are U-shaped.

37. The reel assembly of claim 34, further comprising a package having two side walls, front and rear walls that extend upwards from the base, a window in the front wall and two side wall apertures, wherein the reel stand, the plurality of reels , and the one or more reel interfaces are positioned inside the package.

38. The reel assembly of claim 37, wherein each of the cylindrical cores that extends into the cutout of one or more of the endplates further extends into a respective one of the side wall apertures.

39. A reel assembly comprising: a plurality of reels, each reel having a longitudinally extending cylindrical core and a pair of flanges, wherein each flange of the pair of flanges is positioned at opposing ends of a respective one of the cylindrical cores and has a central flange opening that at least a portion of the respective one of the cylindrical cores extends through and a plurality of apertures that circumscribe the central flange opening; a plurality of reel stands corresponding to each of the plurality of reels, each reel stand having a base and two end plates that extend upwards from opposing ends of the base, wherein each of the end plates includes an inside face, an outside face, a cutout that extends downwards from a top edge of each of the end plate and a set of end plate protrusions radially aligned along at least a portion of the cutout on the inside face of each end plate, wherein each set of end plate protrusions extends into a subset of the plurality of apertures of a respective one of the flanges; and a plurality of cylindrical ring members, each having a diameter slightly less than a diameter of each of the cylindrical cores, wherein each of the cylindrical ring members arepartially nested within a respective one or more of the cylindrical cores and are positioned inside a respective one or more of the cutouts.

40. The reel assembly of claim 39, wherein each of the cutouts is U-shaped.

41. The reel assembly of claim 39, wherein each of the plurality of end plate protrusions is a flap and wherein the end plate protrusions are angled relative to a plane of the associated end plate.

42. The reel assembly of claim 41, wherein each of the flaps includes a ramp surface and a locking surface, wherein the locking surface is generally orthogonal to the associated end plate and the ramp surface is angled relative to the associated end plate along a top edge of the locking surface.

43. The reel assembly of claim 39, further comprising a package having two side walls, front and rear walls that extend upwards from the base, a window in the front wall and two side wall apertures, wherein the reel stand and reels are positioned inside the package.

44. The reel assembly of claim 43, wherein two of the cylindrical ring members extend beyond the respective cutout they are positioned in and extend into a respective one of the side wall apertures.

45. A reel assembly locking mechanism comprising: a first set of apertures circumscribing a first flange positioned at an end of a first reel of a plurality of linearly arranged reels; a second set of apertures circumscribing a second flange positioned at an end of a second reel of a plurality of linearly arranged reels, wherein the first and second reels are adjacent to one another and are joined together by a reel interface comprising: a cylindrical ring member partially nested into each of the first reel and the second reel; andan intermediate disk fitted around the cylindrical ring member, wherein the intermediate disk has a first face and a second face that face opposite directions and a first set of protrusions that circumscribe the intermediate disk and extend outwards from the first face and a second set of protrusions that circumscribe the intermediate disk and extend outwards from the second face; each protrusion of the first and second set of protrusions being a flap having a locking surface that extends generally orthogonally to each respective face of the intermediate disk and a ramp surface that is angled relative to each respective face of the intermediate disk and extends along a top edge of the orthogonal surface; and each of the protrusion of the first and second set of protrusions being oriented in a particular circumferential direction wherein the first set of protrusions align with and extend into at least a subset of the first set of apertures and the second set of protrusions algin with and extend into at least a subset of the second set of apertures.

46. The reel assembly locking mechanism of claim 45, wherein each of the protrusions is U- shaped.

47. The reel assembly locking mechanism of claim 45, wherein the plurality of protrusions are integral with each the intermediate disk.

48. A reel assembly comprising: one or more reels, each reel having a longitudinally extending cylindrical core and a pair of flanges, wherein each flange of the pair of flanges is positioned at opposing ends of a respective one of the cylindrical cores and has a central flange opening that at least a portion of the respective one of the cylindrical cores extends through and a plurality of apertures that circumscribe the central flange opening;one or more reel stands corresponding to each of the plurality of reels, each reel stand having a base and two end plates that extend generally orthogonally from the base, wherein each of the end plates includes a cutout and one or more end plate protrusions radially aligned along at least a portion of the cutout of each of the end plates, wherein one or more of the end plate protrusions extend one or more of the plurality of apertures of a respective one of the flanges; and a plurality of cylindrical ring members, each partially nested within the cylindrical core of one or more of the reels and positioned within one or more of the cutouts.

49. The reel assembly of claim 48, wherein each of the cutouts is U-shaped.

50. The reel assembly of claim 48, wherein each of the plurality of end plate protrusions is a flap and wherein the end plate protrusions are angled relative to a plane of the associated end plate.

51. The reel assembly of claim 50, wherein each of the flaps includes a ramp surface and a locking surface, wherein the locking surface is generally orthogonal to the associated end plate and the ramp surface is angled relative to the associated end plate along a top edge of the locking surface.

52. The reel assembly of claim 48, further comprising a package having two side walls, front and rear walls that extend upwards from the base, a window in the front wall and two side wall apertures, wherein the reel stand and reels are positioned inside the package.

53. The reel assembly of claim 52, wherein two of the cylindrical ring members extend beyond the respective cutout they are positioned in and extend into a respective one of the side wall apertures.

54. A reel assembly comprising:an axle having a pair of endplates, wherein each endplate of the pair of endplates is positioned at an opposing end of the axle, and wherein each endplate of the pair of endplates includes: one or more mounting mechanisms; and one or more endplate protrusions radially aligned around the endplate; one or more reels, each having a longitudinally extending cylindrical core and a pair of flanges positioned at opposing ends of the longitudinally extending cylindrical core, wherein one or more of the flanges have one or more apertures radially aligned around a flange central opening, wherein the one or more endplate protrusions protrude into one or more of the apertures, and wherein the axle is inserted through each of the longitudinally extending cylindrical cores of the one or more reels.

55. The reek assembly of claim 54, wherein a first reel, of the one or more reels, includes a first flange, of the respective pair of flanges, that has a cutout portion and wherein a second reel, of the one or more of the reels includes another first flange, of the respective pair of flanges, that has a set of one or more tabs that protrude into the cutout portion of the first flange of the first reel.

56. The reel assembly of claim 54, wherein the first reel of the one or more reels includes a second flange, of the respective pair of flanges, that lacks the cutout portion and the set of one or more tabs.

57. The reel assembly of claim 56, wherein the second reel of the one or more reels includes another second flange, of the respective pair of flanges, that has another cutout potion.

58. The reel assembly of claim 57, wherein a third reel, of the one or more reels, includes an additional first flange, of the respective pair of flanges, that has an additional set of oneor more tabs that protrude into the other cutout portion of the other second flange of the second reel.

59. The reel assembly of claim 58, wherein the third reel, of the one or more reels, includes an additional second flange, of the respective pair of flanges, that lacks the cutout portion and the set of one or more tabs.

60. The reel assembly of claim 55, wherein the one or more tabs include a pair of tabs.

61. The reel assembly of claim 54, wherein the one mounting mechanisms are fastener holes.

62. The reel assembly of claim 54, wherein the one or more mounting mechanisms include a first, a second, and a third fastener hole.

63. A reel assembly locking mechanism comprising: a first set of protrusions protruding from a first endplate that is positioned at a first end of an axle of a reel assembly; a second set of protrusions protruding from a second endplate that is positioned at a second end of the axle of the reel assembly; one or more reels mounted on the axle, wherein the one or more reels each have one or more flanges attached that include a first exterior flange that is adjacent to the first end plate, a second exterior flange that is adjacent to the second endplate, and a plurality of interior flanges between the first exterior flange and the second exterior flanges; a first set of apertures in the first exterior flange, wherein the first set of protrusions protrude from the first endplate into the first set of apertures; a second set of apertures in the second exterior flange, wherein the second set of protrusions protrude from the second endplate into the second set of apertures; one or more cutout portions in one or more of the plurality interior flanges; andone or more tabs on one or more of the plurality of interior flanges, wherein one or more of the tabs protrude into one or more of the cutout portions.

64. The reel locking assembly of claim 63, wherein the first exterior flange and the second exterior flange lack an additional cutout portion and one or more of the tabs.

65. The reel locking assembly of claim 63, wherein each flange of the plurality of interior flanges includes one or more of the cutout portions.

66. The reel locking assembly of claim 63, wherein each flange of the plurality of interior flanges includes one or more of the tabs.

67. The reel locking assembly of claim 63, wherein the first set of protrusions are radially aligned on the first endplate.

68. The reel locking assembly of claim 63, wherein the second set of protrusions are radially aligned on the second endplate.

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