Adhesively bonded media reel

Abstract

A reel includes first and second flanges and a plurality of staves. The first flange includes a first plate and a second plate formed of a wood-based material. The first plate is secured to the second plate by a first adhesive bonding, and the second plate has a first annular channel. The second flange has a second annular channel. Each of the plurality of staves extends from within the first annular channel to within the second annular channel. At least a first stave is secured in at least one of the first annular channel or the second annular channel by a second adhesive bonding. The plurality of staves collectively form a core surface around which flexible material may be wound between the first flange and the second flange.

Description

ADHESIVELY BONDED MEDIA REELThis application claims the benefit of United States Provisional Patent Application serial no. 63 / 635,851, filed April 18, 2024, the entire contents of which are incorporated herein by reference.Field

[0001] This disclosure relates generally to wound media reels, and, more particularly, adhesively bonded wound media reels.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. Larger wound media necessitates the use of larger size reels formed of strong materials such as, for example, wood. Conventional large wood reels include multiple staves arranged so as to form a cylindrical core, with a disk-shaped outer flange affixed to each end of the cylindrical core. Typically, plywood and hard woods are the materials used for the flanges, while the staves are generally formed of hard wood that may be reinforced with metal or other wood.

[0003] The typical assembly method for a large wood reel includes nailing two layers of wood lumber planks together to form each outer flange, and bolting the flanges together such that the staves are locked together between the flanges. The conventional large wood reel is bolted together using metal bolts that pass through from one end of one of the flanges and thread into metal nuts on the opposite end of the other flange, clamping the staves between the two flanges.

[0004] Using nails, nuts, bolts, or other metal fasteners, however, complicates disposal of the reels. In particular, the metal fasteners that hold the layers of each flange together, which are often nails, must be removed for the reels to be ground up or easily recycled at end of the reels’ life, which is normally not feasible. Moreover, the use of metal nails, bolt, nuts, or other metal contributes a significant portion of both the material cost of the reel and the complexity, and therefore manufacturing cost, of assembling the reels.

[0005] Furthermore, the conventional through-bolt design can result in issues related to the shifting of the slats or staves of the core, which can be disadvantageous to the winding process, and / or the material that is wound on the core.

[0006] There is a need therefore, for a reel design that addresses one or more of the issues or disadvantages discussed above.Summary

[0007] The disclosed reel addresses the above-stated need, as well as others, by providing structurally sound alternatives to the conventional assembly methods that use traditional components to constructed multilayer flanges in a wood-based reel.

[0008] A first embodiment is a reel having a first flange, a second flange, and plurality of staves. The first flange includes a first plate and a second plate, each of the first and second plates formed of a wood-based material. The first plate is secured to the second plate by a first adhesive bonding. The second plate has a first annular channel. The second flange includes a second annular channel. Each of the plurality of staves extending from within the first annular channel to within the second annular channel. At least a first stave secured in at least one of the first annular channel or the second annular channel by a second adhesive bonding. The stavescollectively form a core surface around which flexible material may be wound between the first flange and the second flange.

[0009] In some embodiments the staves are formed of a wood-based product. In some of such embodiments no fasteners are employed other than the adhesive bonding. In other embodiments, bolts may be used to connect the flanges too each other with the staves trapped between the flanges, held in place by the bolts.

[0010] A strong adhesive bonded material connection between the flanges and staves forms a strong joint. The adhesive bonded connection simplifies manufacturing of the reel and provides an economical solution for bonding the staves to the flanges. The adhesive bonded connection of the first and second plate simplifies manufacturing of the flanges and provides an economical solution for bonding the plates to form the flanges.

[0011] Methods for manufacturing the wood flanges include, but are not limited to, bonding two layers of lumber together with the grain of the first layer perpendicular to the grain of the second layer, or at least a rotational offset angle of at least 45 degrees. After curing, the two- layer sheet can be cut into a round structure to form the first flange. At such time, additional features can be machined in to the second plated, such as for example a circular groove or annular channel, commonly referred to as a core nest, for the staves to be seated within. The staves can be cut from lumber or molded from a moldable wood product. The staves are profiled on the outside such that when assembled they form a smooth cylindrical core. Typically, the staves form a fully enclosed cylinder, but it is not always required, as some variations will have open space between each stave. In one embodiment, the edges along the traverse of the stave are cut at an angle such that when all staves are assembled, the mating edges of each stave are parallel and in contact. Each edge angle extends radially toward the theoretical center point ofthe diameter of the fully formed core. Once all staves form the full core diameter, along the traverse edges the angle of the mating edges prevent the staves from condensing inward towards the center point any further. In one embodiment, the staves can all have the same angle, while in other embodiments one or more of the staves have a smaller or larger angle. The assembly can be achieved by utilizing a fixture to allow for consistent manufacturing. The bonding agent is applied in the core nest in the flange and then the staves are interposed between first said flange and second said flange.

[0012] The strong joint bond between the stave(s) and the flanges prevents the staves from shifting circumferentially around the core nest when cable is wound or unwound on the reel. Said shifting can cause what is referred to in the industry as cable creep, or the gradual unwinding or loosening of a cable from a reel, even when not actively being pulled. Because the staves are bonded to the flanges tension on the winding will not cause the staves to shift independently from the flanges. The permanent bond between staves and flanges also allows the wire manufacturer or rewinder to increase winding tension to prevent excessive cable creep such as, but not limited to, vibration, improper winding, and gravity. The permanent bond of the staves to the flanges will further prevent the staves from shifting inward radially which further prevents cable creep due to a loosening of the wire or cable coil. In one embodiment a single stave can be adhesively bonded to the flanges and the remainder of the reel can be assembled together with traditional method of bolts and nuts. The permanent bond of one stave will thus prevent the remaining staves from shifting circumferentially and causing cable creep. Another embodiment can have any number of staves less than the total amount of staves to make the complete core bonded to the flange core nest(s). Yet another embodiment could have a section in the core nest groove that is recessed to allow for a single stave that is equal to the same lengthof the other staves, plus the groove depth of each flange. This embodiment can use nuts, washers and bolts as the preferred method for mating the remaining staves to the flanges. Other methods for mating the flanges to the staves can include but not limited to a plurality of sustainable nails formed of wood or a different recyclable material, for example paper, paperboard, plastic, fiberboard, composites, and the like.

[0013] The above-described features and advantages, as well as others will become more readily apparent to those of ordinary skill in the ail by reference to the following detailed description and accompanying drawings.Brief Description of the Drawings

[0014] Fig. 1 is a front perspective view of an exemplary embodiment of a reel according to the disclosure.

[0015] Fig. 2 is an exploded view of the reel of Fig. 1.

[0016] Fig. 3 is a side view of the reel of Fig. 1 .

[0017] Fig. 4 is a cross-sectional side view of the reel of Fig. 1.

[0018] Fig. 5 is a detail view of region V of Fig. 4.

[0019] Fig. 6 is an exploded view of an alternative embodiment of the reel according to the disclosure.

[0020] Fig. 7 is a cross-sectional side view of the reel of Fig. 6.

[0021] Fig. 8 is a detail view of region X of Fig. 7.

[0022] Fig. 9 is a cross-sectional side view of another embodiment of the reel according to the disclosure.

[0023] Fig. 10 is a detail view of region XII of Fig. 9.

[0024] Fig. 11 is a cross-sectional side detail view of a groove and bonding arrangement that may be used in a reel according to the disclosure.

[0025] Fig. 12A is a side view of a first step in the installation of a stave into the groove and bonding arrangement of Fig. 11.

[0026] Fig. 12B is a side view of a second step in the installation of the stave into the groove and bonding arrangement of Fig. 11.

[0027] Fig. 12C is a side view of a third step in the installation of the stave into the groove and bonding arrangement of Fig. 11.

[0028] Fig. 12D is a side view of the installation of the remaining staves into the groove and bonding arrangement of Fig. 11.

[0029] Fig. 13 is a cross-sectional side detail view of another embodiment of a groove and bonding arrangement that may be used in a reel according to the disclosure.

[0030] Fig. 14 is an exploded view of a different embodiment of the reel according to the disclosure.

[0031] Fig. 15 is a fragmentary cutaway radially outward looking view of an alternative reel according to the disclosure, taken along line XV of Fig. 15A.

[0032] Fig. 15A shows a top schematic view of the flange of the reel of Fig. 15.

[0033] Fig. 16 shows process diagram of a method for producing the reel of Fig. 1.Detailed Description

[0034] For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by thereferences. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains.

[0035] Fig. 1 depicts a front perspective view of an adhesively bonded reel 100 according to a first embodiment. Fig. 2 shows an exploded perspective view of the reel 100, Fig. 3 shows a side plan view of the reel 100, and Fig. 4 shows a cutaway side view of the reel 100. Fig. 5 is a detail view of region V of Fig. 4. With reference to Figs. 1 to 5, the reel 100 includes a first flange 112a, a second flange 112b, and a plurality of staves 108 that collectively form a core 104 around which flexible media, such as cable, wire or the like, may be wound.

[0036] The first flange 112a includes a first (outer) plate 124a and a second (inner) plate 120a. Each of the plates 120a, 124a is formed of a wood-based material, such as cellulose wood, a wood-derived product such as plywood, or wood planks, hr some cases, the plates 120a, 124a can be another rigid material. The first plate 124a is secured to the second plate 120a by a first adhesive bonding. In this embodiment, the first plate 124a has a first wood grain direction 121a, and the second plate 120a has a second wood grain direction 121b. The first plate 124a is secured to the second plate 120a such that the first wood grain direction 121a and the second wood grain direction 121b are offset by a rotational angle of at least about 45 degrees, and preferably such that they are substantially perpendicular. This enhances the strength of the flange 112a.

[0037] The plates 124a, 120a in this embodiment are formed as disks which are concentrically aligned to form a two-layer disk structure as shown in Figs. 3 and 4. The first flange 112a also includes a central arbor hole 101a and drive holes, both of which extending through both the first plate 124a and the second plate 120a, as shown in Fig. 2. The second plate 120a has a firstannular channel 140a, formed therein, which is also known in the art as a core nest groove or channel.

[0038] In this embodiment, the first adhesive bonding is a layer of adhesive 128a (see Fig. 2) that is applied on between the facing surfaces of the first plate 124a and the second plate 120a. In this embodiment, the adhesive 128a may be, for example, a low surface energy bonding film, a two-part adhesive epoxy, or an adhesive spray. As discussed above, the adhesive 128a is applied to the facing surfaces of the inner and outer plates 120a, 124a. Activation and / or setup may be applied to the plates 120a, 124a, depending on type of adhesive agent used.

[0039] The second flange 112b in this embodiment has an identical structure to the first flange 112a, and includes a first plate 124b and a second plate 120b. Each of the plates 120b, 140b is formed of a wood based material, such cellulose wood, a wood derived product such as plywood, wood planks, or another rigid material. The first plate 124b is secured to the second plate 120b by a similar adhesive bonding. The adhesive bonding is again a layer of adhesive 128b (see Fig. 2) that is applied on between the facing surfaces of the first plate 124b and the second plate 120b. The plates 124b, 120b in this embodiment are formed as disks which are concentrically aligned to form a two-layer disk structure as shown in Figs. 3 and 4. The second flange 112b also includes a central arbor hole 101b and drive holes 103b, both of which extending through both the first plate 124b and the second plate 120b, and align with the respective arbor hole 101a and drive holes of the first flange 112a. Similar to the first flange 112a, the second plate 120b of the second flange 112b has a second annular channel 140b, formed therein to form a core nest.

[0040] Each of the plurality of staves 108 extend from within the first annular channel 140a to within the second annular channel 140b (see Fig. 4). At least one of the staves 108 is secured in either or both of the first annular channel 140a and / or the second annular channel 140b by asecond adhesive bonding. In this embodiment, the adhesives 144a and 144b form adhesive bondings between each of the staves 108 and the respective flanges 112a, 112b. To this end, the adhesive 144a is disposed in the channel 140a where it bonds to and between an end of each of the staves 108 and one or more walls of the channel 140a, and the adhesive 144b is disposed in the channel 140b where it bonds to and between the other end of each of the staves 108 and one or more walls of the channel 140b. The staves 108 are arranged around to form, essentially, a hollow cylindrical core 104. The staves 108 thereby collectively form a core surface around which flexible material may be wound between the first flange and the second flange.

[0041] In the illustrated embodiment, the core 104 includes ten staves 108, which are arranged so as to form a closed cylindrical core 104. The core 104 need not be strictly cylindrical in the sense that the cross-section may be not precisely circular. Moreover, it will be appreciated that any desired number of staves 108 may be used in other embodiments. In one embodiment, the edges along the traverse of the staves 108 are cut at an angle such that when all staves 108 are assembled, the mating edges of the adjacent staves 108 are parallel and in contact. Each edge angle extends radially toward the theoretical center point of the diameter of the fully formed core 104. Once all staves 108 form the full core diameter, along the traverse edges the angle of the mating edges prevent the staves 108 from condensing inward towards the center point any further. In one embodiment, staves 108 all have the same arc length, while in other embodiments, the core 104 may have one or more staves 108 with a smaller or larger arc lengths. Additionally, in some embodiments, adjacent staves 108 may be spaced apart from one another, thereby leaving axial gaps in the core 104 running along the axis of the reel 100.

[0042] The staves 108 are configured to extend between, and to be seated within, the annular grooves 140a, 140b. The adhesive 144a, configured in the embodiment of Figs. 1-5 as anannular disk, at least after application. As shown in Fig. 5, the adhesive 144a, arranged in the groove 140a between the end surface of the staves 108 and the base 140al of the groove 140a. The adhesive 144b is similarly arranged in the annular groove 140b between the opposite end surface of the staves 108 and the base of the groove 140b. The adhesives 144a, 144b, bond the staves 108 to the base of the grooves 140a, 140b so as to affix the staves 108 to the flanges 112a, 112b, respectively. To this end, it is noted that the adhesives 128a, 128b, 144a, 144b are specifically selected as those that bond to wood and wood-derived materials.

[0043] It will be appreciated that in some embodiments, the adhesives 144a, 144b are configured to encompass not only the base (i.e. bottom surface) of the corresponding grooves 140a, 140b and the end surface of the staves 108, but also the interior side surfaces of the grooves 140a, 140b (e.g. side surfaces 140a2, 140a3 of groove 140a) and the portions of the exterior side surfaces of the staves 108 that are within the grooves 140a, 140b. In such a case, the adhesives 144a, 144b adhere to three surfaces of the grooves 140a, 140b and three surfaces of the staves 108, thereby providing a stronger connection.

[0044] Figs. 6 to 8 illustrate another embodiment of a reel according to the disclosure, denoted with reference numeral 200. The flanges 212a, 212b have structures similar to the flanges 112a, 112b of Figs. 1-5, except that they have no adhesive layer between flange plates. More specifically, the flange 212a of the reel 200 includes a first, or inner, plate 220a and a second, or outer, plate 224a, and the flange 212b also includes corresponding first and second plates 220b and 224b. As will be explained in detail below, the bond between the staves 108 and the respective flanges 212a, 212b also serves to adhere the two plates 220a, 224a to each other, and the two plates 220b, 224b to each other.

[0045] With specific reference to the flange 212a, the inner plate 220a includes a groove 240 formed as an annular groove portion 260 with a plurality of through-hole portions 264 that extend axially through the plate 220a. In the illustrated embodiment, the through-hole portions 264 are round holes, though in other embodiments the through-hole portions 264 may have another shape and / or include grooves, textures, or other features to facilitate adhesion of the adhesive 244. The outer plate 224a also includes a groove 268 formed as an annular groove that is generally aligned radially and circumferentially with the annular portion 260 of the groove 240a.

[0046] In this embodiment, the annular groove 268 is formed in the surface of the outer plate 224a that is adjacent to the inner plate 220a. As such, the groove 268 may be easily formed in surface of the outer plate 224. In this embodiment, the groove 268 has a radial width that is wider than the through holes 264 to increase the bonding surface area of the adhesive 244a, and to provide an area 245 where the adhesive 244a will directly contact opposing surface areas of the plates 220a, 224a.

[0047] The adhesive 244a is either applied in the through hole portions 264 or is configured to flow from the annular groove portion 260, though the through hole portions 264, and into the groove 268 in the outer plate 224a. In addition, as is best seen in Fig. 8, the adhesive 244 flows up the sides of the staves 108, such that the adhesive bonds to three surfaces of the staves 108, the sides and base of the annular groove portion 260, the sides of the through hole portions 264, the base of the groove 268 of the outer plate 224a, and the area 245 where the surface of the inner plate 220a faces the groove 268. As a result, the adhesive 244a not only forms a strong connection between the staves 108 and the inner plate 220a, but also locks the inner plate 220a and the outer plate 224a together by creating a shoulder, undercut, or nail head effect in the area245. Consequently, the adhesive 244a may, in some embodiments, be used in place of the adhesive between the inner and outer plates 120a, 124a of the embodiment of Figs. 2-5. In some cases, adhesive may be used between the inner and outer plates 220a, 224a, but only located in the radially outer regions of the interface between the plates 220a, 224a.

[0048] The plates 220b, 224b of the flange 212b are constructed and connected in the same manner as the plates 220a, 224a.

[0049] Another configuration of a reel 300 according to the disclosure is illustrated in Figs. 9 and 10. The reel 300 is largely similar to the reel 200, and like structures have the same reference numbers. Generally, the reel 300 includes modified flanges 312a, 312b, which are similar to the flanges 112a, 112b of Figs. 1-5, except for their interface with the staves 108. Similar to the flanges 112a, 112b, the flange 312a of the reel 300 includes a first, or inner, plate 320a and a second, or outer, plate 324a, and the flange 312b includes corresponding first and second plates 320b and 324b. Each of the flanges includes the groove and bonding arrangement 380 as will be described below in reference to the first flange 312a.

[0050] In particular, in the groove and bonding arrangement 380 of the reel 300, the inner plate 320a includes an annular groove 340 that is cut entirely through the inner plate 320a of the flange 312a, thereby separating the inner plate 320a into an inner disk 328 and an outer annular portion 332. The groove 340 has a generally constant radial width that is slightly greater than the radial width of the staves 108 such that the staves 108 extend through the groove 340. In addition, the outer plate 324a includes a groove 368 having a dovetail portion 372 that projects, in the illustrated embodiment, radially and axially inwardly. The groove 368 extends down from the surface 325 of the outer plate 324a that faces and contacts the inner plate 320a.

[0051] The dovetail portion 372 of the groove 368 includes an angled sidewall, configured such that the radial width of the groove 368 at the axial bottom 372a of the dovetail portion 372 is wider than the radial width of at least one portion of the groove 368 located closer to the surface 325. It will be appreciated that in other embodiments, the dovetail portion 372 may project radially outwardly or both radially inwardly and outwardly. Although the bottom of the dovetail portion 372 is also the bottom of the groove 368 in this embodiment, it is not necessary.

[0052] The staves 108 are arranged extending through the groove 340 and into the groove 368. The adhesive 344 surrounds three surfaces (bottom edge and two sides) of the staves 108, and also extends into the dovetail portion 372. As a result, the adhesive 344 not only bonds the staves 108 to the grooves 340, 368, but also, once cured, forms a positive mechanical connection with the dovetail portion 372 to strengthen the adhesive connection between the staves 108 and the grooves 340, 368. The second flange 312b is constructed in the same manner.

[0053] Figs. 11 and 12A-D illustrate another groove and bonding arrangement 480 that may be used instead of the bonding arrangement 380 in the reel 300 of Figs. 9 and 10. Fig. 11 shows a fragmentary cutaway portion of a reel 300’ that generally has the same structures as the reel 300. Figs. 12A to 12D show top schematic view illustrating the assembly of the groove and bonding arrangement 480. In this embodiment, the staves 408 differ from the staves 108, as will be discussed below.

[0054] Generally, the reel 300’ includes a first flange 412, a second flange, not shown (but identical to the flange 412, and a core 404. The first flange 412, which is similar to the flanges 112a, 112b of Figs. 1-5, except for their interface with the staves 408. Similar to the flanges 112a, 112b, the flange 412 of the reel 300’ includes a first, or inner, plate 420 and a second, or outer, plate 424. The flange 412 includes the groove and bonding arrangement 480. In general,the inner plate 420 includes an annular groove 440 that is cut entirely through the inner plate 420 of the flange 412, thereby separating the inner plate 420 into an inner disk 428 and an outer annular portion 432. The groove 440 has a generally constant radial width. In addition, the outer plate 424 includes a groove 468 having a dovetail portion 472 that projects, in the illustrated embodiment, radially inwardly. The groove 468 extends down from the surface 425 of the outer plate 424 that faces and contacts the inner plate 420. The dovetail portion 472 extends radially inward as it extends axially from the surface 425.

[0055] In the bonding arrangement 480, the staves 408 include a channel 488 defined into the inward-facing surface of the stave 408, forming a protruding dovetail portion 492 that is complementary to a corresponding dovetail portion 472 of the groove 468 of the outer plate 124. In this embodiment, the channel 488 also defines a wider main stave portion 489 that is disposed above the groove 440.

[0056] The assembly of the staves 408 to the flange 412 is shown in Figs. 12A to 12D. It will be appreciated that the inner disk 428 may be separately secured to the outer plate 424 by an adhesive disposed on the abutting surfaces of the inner disk 428 and the outer plate 424 to form the structure of Fig. 12A.

[0057] As shown in Figs. 12A to 12B, the reel 300’ is constructed with a winding start hole 200 that is located tangential, or in close proximity, to the outside diameter of the annular groove 440. In the illustrated embodiment, the start hole 200 is in the form of a partial circular hole that extends through the outer annular portion 432 of the inner plate 420 adjacent to and overlapping with the groove 440. The start hole 200 also extends through the outer plate 424 adjacent to and overlapping with the groove 468. In this embodiment, the start hole 200 forms a lateral opening in the grooves 440, 468 that can be utilized as the lateral or radial insertion point of the staves408. This allows for tighter tolerancing between the annular grooves 440, 468 and the staves 408, particularly with the dovetail portions 472, 492 securing the stave 408 into the annular grooves 440, 468. To the extent the start hole 200 overlaps with the groove 468, it does not need to extend completely through, which facilitates assembly of the stave 408 in this location.

[0058] In particular', each stave 408, has the same or a similar shape as the corresponding grooves 440, 468. The staves 408 also have the same or similar outer surface profile to match the outside diameter of the grooves 440, 168. After the flange 412 and the opposing flange are assembled in a manner similar to that described above for the flanges 112a, 112b, the staves 408 are inserted into the start hole 200 and then laterally into the grooves 440, 468 as shown in Figs. 12A and 12B. To this end, the through hole 200 is larger in size than the staves 408 such that one of the staves 108E can be positioned axially in the start hole 200 (Fig. 12A), and then moved radially inwardly such that the protruding dovetail portion 492 of the stave 408 engages the dovetail portion 472 of the groove 468 (Fig. 12B). After initial insertion adjacent to the start hole 200, each stave 408 is then moved in an annular direction through the grooves 440, 468 to its desired annular position (Fig. 12C). Fig. 12D illustrates the positions of the plurality staves 408 after insertion. This assembly method saves considerable manufacturing time, while also strengthening the stave-to-flange joint.

[0059] As illustrated in Fig. 11, the dovetail portion 492 of the stave 408 forms a positive mechanical connection between the stave 408 and the outer plate 424, thereby inhibiting axial movement of the stave 408 relative to the flange 412. As with the aforementioned embodiments, the groove and bonding arrangement 480 also includes an adhesive 444 that fills the gap between the staves 408 and the walls of the grooves 440, 468, which inhibits circumferential or annular movement of the staves 408 and further supporting the axial fixation of the staves 408. Thus, thegroove and bonding arrangement 480 enables a particularly strong mechanical and adhesive connection between the staves 408 and the flange 412.

[0060] Fig. 13 illustrates another embodiment of a groove and bonding arrangement 480’ that is similar to, and may be used as an alternative to the groove and bonding arrangement 480 of Fig. 11 in the reel 300’. In the groove and bonding arrangement 480, the groove 468’ has the same structure as the groove 468, except that it further includes a dovetail portion 474 on the radially outside portion of the outer plate 424, in addition to the dovetail portion 472 on the radially inside portion of the outer plate 424.

[0061] The staves 408’ of the embodiment of Fig. 13 have the same structure as the staves 408, except that the radially outer surface of each stave 408’ includes a channel 490 forming a dovetail portion 494 that is complementary to the dovetail portion 474. In the embodiment of Fig. 13, therefore, the two dovetail portions 492, 494 of each stave 408 form a positive mechanical connection to the dovetail portions 472, 474 both radially outward and radially inward of the grooves 440, 468, in addition to adhesive connection provided by the adhesive 444. Further, the reader should appreciate that, in some embodiments, the groove and bonding arrangement may include a dovetail portion on only the radially exterior portion of the interface between the stave and the flange.

[0062] In some embodiments, the annular groove may be formed in a different shape than illustrated in the embodiments described above. In particular, the groove may have a U-shape, a V-shape, a trapezoidal shape, a triangular shape, and / or a tongue and groove interlocking shape that enables the adhesive to be locked between two flange plates. In another embodiment, the trapezoidal dovetail cut can be on the outside diameter, inside diameter (e.g. Fig. 11), or a combination of both inside and outside diameters of the groove (e.g. Fig. 13). The groove mayalso be used in conjunction with other design elements to provide further interlocking strength of the joint, such as holes or additional grooves.

[0063] In one embodiment a plurality of wood or other material can be used as spacers uniformly located inside the core nest to prevent the staves from being compressed fully into the core nest, preventing the adhesive from being forced out of the bottom of the nest. In this embodiment, the adhesive content compared to the total reel volume is less than 0.5%.

[0064] While the illustrated embodiments depict the inner and outer plates of the flange having substantially equal thicknesses, the reader should appreciate that in some embodiments, the plates may have different thicknesses. For example, in embodiment in which the groove depth extends into the outer flange, the inner plate thickness can be considerably thinner than the outer plate since the bond strength is primarily provided by the bond of the stave to the groove extending into the outer flange plate. The reduction in thickness of the inner plate provides considerable manufacturing and material cost reduction.

[0065] Another embodiment of the design utilizes staves that uniformly form a cylinder around the core nest but have spacing between each stave. This configuration can lower production costs by reducing material needed. Because the bonding material permanently affixes the staves to the flange, there is no risk of the staves moving within the core nest. In place of a fully annular groove in the flange, mating pockets can be manufactured into the flange by routing, milling or another manufacturing method.

[0066] In some cases, the connection between the staves and the flanges can be enhanced by fasteners, such as those that extend from one flange to the other. Fig. 14 shows an exploded view of an alternative reel 100’ that is identical to the reel 100, except that it further includes bolts or other fasteners 189a that extend from the outer plate 124b of the second flange 112b tothe outer plate 124a of the first flange 112a. In this example, the fastener 189a is secured by a corresponding nut 189b. The fasteners 189 help hold the flanges 112a, 112b axially onto the core 104. Additionally, the core 104 needs to be engaged to the flange 112a, 112b such that the core 104 cannot rotate or move independently of the flanges 112a, 112b. Rotation of the core relative to the flanges can cause failure of the flexible product to be wound onto the reel, or conversely to be unwound off the reel. To address this issue, the adhesive may nevertheless be used one or all of the staves 108 (within the core nest groove 140) to prevent rotation of the core 104. By adhering one or more staves 108 permanently to the flange 112a, this prevents any unwanted movements. The need for metal fasteners for one of more of the staves may be avoided this way.

[0067] In other embodiments that use fasteners, for example, other methods for preventing rotation of the core 104 and / or other movement or shifting of the staves may be employed. For example, the annular core nest groove (e.g. grooves 144 and / or 168) may include a first indexing feature at or within a particular annular position that receives a second indexing feature on the end of the stave, which serves to annular movement of the first stave.

[0068] Fig. 15, for example, shows a fragmentary cutaway of a version of the reel 100 of Fig. 1 from where the annular groove 140 includes a first indexing feature 195 in the form of a notch that extends down from the bottom of the groove 140 at a first annular location 199. Fig. 15A shows a top schematic view of the flange 112a of Fig. 15 for reference as to the location of the cutaway XV used in Fig. 15.

[0069] In this embodiment, at least one stave 108’ has a corresponding knob or tab the forms a second indexing feature 197 that is received by the first indexing feature 195. The second indexing feature 197 extends from the axial end of the stave 108’. When the stave 108’ isdisposed in the first annular location 199, the second indexing feature 197 can be inserted into the first indexing feature 195 to retain the stave 108’ at the first annular location 199. The other staves 108 need not include an indexing feature, because when the core 104 is completed, the other staves 108 cannot rotate because the stave 108’ cannot rotate due to the indexing features 195, 197. It will be appreciated that adhesive 144 may still be used in the groove 140 (and indexing feature 195) to further inhibit any movement. It will also be appreciated that in other embodiments multiple staves 108’ may be used, or even all staves 108’ may be used, so long as the groove has corresponding indexing features 195.

[0070] Fig. 16 illustrates a process diagram of a method 600 for producing a reel such as the reel 100 described above. The same general method may be used to assemble the other reels 200, 300, and 300’. The method 600 begins with preparing the flanges 112a, 112b in the manner described above. Thereafter, the method 600 includes inserting the adhesive 144 into the annular core nest groove 140 (or core nest grooves 240 / 268, grooves 340 / 368 etc.) of one of the flanges 112a (block 610). The adhesive 144 may be, for example, a two-part foaming epoxy structural foam / adhesive, a non-foaming adhesive with a greater peel performance strength, a wood glue resin, which may be thickened with structural fillers to prevent the glue from oversoaking into the wood and minimizing gaps in the assembly joints. The adhesive 144 may be extruded directly onto the flange 112a or into the groove 140, it may be formed as an injection molded ring or cord, or it may be applied via spraying into the groove 140. In particular, the flange 112a may be arranged in a fixture with the annular groove 140, facing vertically upward to enable the insertion of the adhesive 144 into the annular grooves 140. The adhesive, in any form of application process considered, may be a continuous bead or a plurality of bead locations within the groove. If used in a spray process, there can be one or more areas of spray coverage.

[0071] The method 600 further includes inserting the staves 108 into the grooves 140, 168 (block 420). The staves 108 may be inserted into the groove 140 axially in the embodiments of Figs. 1-8, or, for example, as discussed above in connection with the groove and bonding arrangements 380, 480. The core 104 is then axially inserted into the annular groove 140 of the flange 112a while the flange 112a is mounted in the fixture.

[0072] In some embodiments, the staves 108 are placed into a fixture or jig and are temporarily fastened together utilizing, for example, locking straps or other similar devices, to apply pressure in the radial direction to form the cylindrical core 104. Alternatively, the staves 108 may be adhesively bonded to one another to form the core 104. In one embodiment of using adhesive between the staves 108, low radial pressure may be applied during the adhesive setup time to provide a tight fit between the staves 108, allowing for better bonding compression strength.

[0073] The method proceeds 600 with curing of the adhesive 144 (block 430). In some embodiments, axial pressure is applied to press the core 104 into the flange 112a before or while the adhesive 144 is cured so that the adhesive 144 expands to fill the gaps between the staves 108 and the groove 140. Further, certain adhesives, for example foaming adhesives, may expand to further fil the gaps between the staves 108 and the grooves 140, 168. In one embodiment using foaming adhesive, when cured, the foaming adhesive will expand approximately 150 percent or less of pre-expansion volume. The adhesive will densify when confined, such that it will account for tolerance issues and densify into the gap between the stave and nest but does not expand violently and cause any warpage or tolerance deviations. The adhesive will also expand into any natural or artificially manufactured gaps. In another embodiment using non-foaming adhesive, the quantity of adhesive used, in conjunction with the axial and radial pressure applied forcuring, can fill into the gaps between the staves, groove profile, and any natural or artificially manufactured gaps.

[0074] Once the adhesive 144 is cured, steps 610, 620, and 630 are repeated to connect the other flange 112b on the opposite end of the core 104 (block 640). For instance, the opposite flange 112b may be connected to the assembly of the core 104 and flange 112 while the flange 112a remains in the fixture, or the assembly of the core 104 and flange 112a may be removed from the fixture before attachment of the opposite flange 112b.

[0075] It will be appreciated that the steps of the method 600 need not be completed in the order shown in Fig. 16. For example, the adhesive may, in some embodiments, be inserted into the groove after the insertion of the staves into the groove. Additionally or alternatively, the opposite flange may be connected to the assembly of the core and first flange prior to curing the adhesive.

[0076] This disclosure provides a design that provides a strong adhesive bonded material connection between the flanges and staves, forming a strong joint. The adhesive bonded connection simplifies manufacturing of the reel and provides an economical solution for bonding the staves to the flanges. In addition, some embodiments of the disclosure include a mechanical connection that supplements the adhesively bonded connection.

[0077] The disclosed reel 100 results in an assembly that has a small amount of non-wood (e.g. ferrous) material. For example, the reel 100 may have less than 5% non-wood material or, more particularly, less than 1% non-wood material. As a result, the reel 100 can be easily disposed of by, for example, shredding, sorting, and recycling. Specifically, at the end of the reel’s life, the reel 100 may be broken down, i.e. shredded, with no product preparation required. Further, whennon-toxic bonding material is used, the used reel 100 may be used as biomass fuel or wood-to- energy incineration.

[0078] Further, the flange 112a of the disclosed reel 100 has a recessed annular groove, or core nest, that facilitates mounting and centering of the staves / core onto the flange. The recessed annular groove also reduces the proclivity of the bonding material to flow past the inner surface of the flange 112a where it might impinge on the media wound around the core 104. Further, the core nest also provides a plurality of bonding surfaces between the staves 108 and flanges 112a.

[0079] Additionally, in some embodiments, the depth of the groove penetrates through the inner plate of the flange and into the outer plate. This allows the adhesive to adhere to the grain of the outer plate. By adhering the core staves to the groove in the outer plate, the inner plate, which may have perpendicularly aligned wood fibers, provides increased cellulose strength at the joint.

[0080] In the reel disclosed herein, the adhesive bond provides a permanent joint between the flanges and the staves / core, which improves the reel’s strength to hold up to rigors of handling, winding torque, vibrations, or impact forces. The adhesive bond also resists the tendency of the staves to shift within the core nest.

[0081] Further, reducing the gap tolerance of the groove and core increases densification and bonding strength of the adhesive. For instance, typical tolerance for the groove to account for expansion and contraction of lumber due to heat, humidity, and other tolerances within the manufacturing process can be a minimum of 1 / 32” to nominal OD and 1 / 32” to nominal ID. In one embodiment, with a core nest ID / OD gap smaller than the allowable space needed for the adhesive to expand into, the adhesive only adheres to one surface, creating a butt joint (e.g. Fig. 5). In this embodiment, the adhesive content compared to the total reel volume is particularlylow, for example less than 0.5%. In other embodiments (e.g. Figs. 7, 10, 12, 13, and 15), the gap between the grove in the flange(s) and the ID and / or OD of the staves is large enough for the adhesive to expand to fill in the gap. As a result, adhesive contact is provided on two or more surfaces, creating a superior bond than only one surface (butt joint). In this embodiment, the quantity of adhesive can still be minimized and can be, for example, less than 0.5% of the total reel volume.

[0082] An apparatus for supporting wound flexible media includes first and second flanges and staves that form a cylindrical core. Methods for manufacturing the wood flanges consist of, but not limited to, bonding two layers of lumber together with the grain of the first layer perpendicular to the grain of the second layer. After curing, the double layered sheet can be cut into a round flange, with additional features machined in at this time, including a circular’ groove, commonly referred to as a core nest, for the staves to rest in. The staves are made from cut or molded lumber. The staves are profiled on the outside such that when assembled they form a smooth cylindrical core. Typically, the staves form a fully enclosed cylinder, but it is not always required, as some variations will have open space between each stave. In one embodiment, the edges along the traverse of the stave are cut at an angle such that when all staves are assembled, the mating edges of each stave are parallel and in contact. Each edge angle extends radially toward the theoretical center point of the diameter of the fully formed core. Once all staves form the full core diameter, along the traverse edges the angle of the mating edges prevent the staves from condensing inward towards the center point any further. In one embodiment, staves can all have the same angle, or can have one or more staves with a smaller or larger angle. The assembly can be achieved by utilizing a fixture to allow for consistent manufacturing. Thebonding agent is applied in the core nest in the flange and then the staves are interposed between first said flange and second said flange.

[0083] It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the foregoing disclosure.

Claims

What is claimed is:

1. A reel, comprising: a first flange including a first plate and a second plate, each of the first and second plates formed of a wood-based material, the first plate secured to the second plate by a first adhesive bonding, the second plate having a first annular channel; a second flange having a second annular channel; and a plurality of staves, each stave extending from within the first annular channel to within the second annular channel, at least a first stave secured in at least one of the first annular channel or the second annular channel by a second adhesive bonding; wherein the plurality of staves collectively form a core surface around which flexible material may be wound between the first flange and the second flange.

2. The reel of claim 1, wherein the first plate has a first wood grain direction, and the second plate has a second wood grain direction, and wherein the first plate is secured to the second plate such that the first wood grain direction and the second wood grain direction are offset by an angle of at least about 45 degrees.

3. The reel of claim 2, further comprising at least a first fastener extending from the first flange to the second flange.

4. The reel of claim 2, wherein the staves are formed of a wood-based material.

5. The reel of claim 4 wherein the staves are disposed adjacent to each other to form a substantially continuous reel core.

6. The reel of claim 4, wherein each of the first adhesive bonding and the second adhesive bonding is formed from at least one of the group consisting of: a low surface energy bonding film; a two-part adhesive epoxy; or an adhesive spray.

7. The reel of claim 1, wherein each of the first adhesive bonding and the second adhesive bonding is formed from at least one of the group consisting of: a low surface energy bonding film; a two-part adhesive epoxy; or an adhesive spray.

8. A reel, comprising: a first flange including a first plate and a second plate, each of the first and second plates formed of a wood-based material, the first plate secured to the second plate by an adhesive, the second plate having a first annular channel; a second flange having a second annular channel; a plurality of staves, each stave extending from within the first annular channel to within the second annular channel and arranged adjacent to each other to form a substantially continuous core surface around which flexible media may be wound, at least a first stave of the plurality of staves fixed in a first annular position within the first annular channel and in a second annular position within the second annular channel independent of a presence of others of the plurality of staves; andat least one fastener extending from the first flange to the second flange to secure the first flange and the second flange against the plurality of staves.

9. The reel of claim 8, wherein the first plate has a first wood grain direction, and the second plate has a second wood grain direction, and wherein the first plate is secured to the second plate such that the first wood grain direction and the second wood grain direction are offset by an angle of at least about 45 degrees.

10. The reel of claim 9, wherein the staves are formed of a wood-based material.

11. The reel of claim 8, wherein the staves are formed of a wood-based material.

12. The reel of claim 11, wherein the first stave is fixed in the first annular position using adhesive bonding.

13. The reel of claim 11, wherein: the first annular channel includes a first indexing feature at or within the first annular position; and the first stave includes a second indexing feature at a first end thereof, configured to engage the first indexing feature to inhibit annular movement of the first stave.

14. The reel of claim 10, wherein the first indexing feature is a recessed portion of the first annular channel.

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