Note: Descriptions are shown in the official language in which they were submitted.
~5~
AN IMPROVED COIL PACKAGE
This invention relates to the packaging of wire or
cable and more particularly to the packaging of coils of
bare or insulated electric wire or cable, for example
wire or cable of the kinds used in house wiring systems,
all such bare and insulated wire and cable hereinafter,
for convenience, being included in the generic term
"wire".
By a "coil" of wire i9 meant a self-suporting
multiplicity of turns or convolutions of wire.
The interest~ of the manufacturer, wholesaler or
retailer, and user of wire are in conflict 1nsofar as
transportation and packaging of wire are concerned. For
ease of manufacture and transportation within the
factory, it i9 in the interests of the manufacturer that
wire used within the factory be in coil form. From the
point of view of the wholesaler or retailer who has to
keep a large stock of wires of different kinds from one
another, storage of wire is facilitated if it is
supplied in packages of a shape and size such that they
can be readily stacked. On the other hand, the user
prefers wire to be supplied on a reel from which wire
can be readily unwound as and when required. Generally,
wire is marketed either in coils which are covered by a
toroidal lapping of paper or cheap fabric or on non-
returnable reels. The former type of packaging is cheapbut it is not popular with wholesalers and retailers
2.
because such packaged coils are not readily stackable
and is not popular with users because wire cannot be
readily withdrawn from a coil and because once the
toroidal lapping is removed to enable wire to be
withdrawn from the coil, the balance of the coil is lef't
unprotected and may become tangled, as replacement of
the toroidal lapping is usually too tiresome to be
undertaken by the user. The alternative form of
packaging in non-returnable reels is unpopular with the
wire manufacturer because it is more labour Lntensive
and costly and is disliked by the wholesaler and
retai~ler because reels cannot be readily stacked.
Several forms of wire packages have been proposed
that serve the dual purpose of a container or carton f`or
a coil and a reel from which wire from the coil can be
readily withdrawn but all suf~er from the disadvantage
that they are not easily stacked for storage purposes
and/or, once the container or carton has been opened to
withdraw wire ~rom the coil, are not readily re-closed
for the purpose of protecting that part of the coil
remaining in the package.
It is the object of the present invention to
provide an improved coil package which serves the dual
purposes of a wire carton and reel, which i9 simple and
inexpensive to manufacture and which, in its preferred
form, can be readily stacked and provides for ready
removal and replacement of` the carton.
ss~
3.
According to the invention our improved coil
package comprises a closable carton which is formed from
at least one folded blank of cardboard or plastics
material and which has a pair of oppositely disposed
major side walls, each of which major side walls has an
aperture in substantially axial alignment with the
aperture of the other major side wall; a pair of
separately formed substantially flat reel flanges, each
of which reel flanges is adjacent to the inner face of
one of the ma~or side walls and each of which reel
flanges has an aperture in substantlally axial alignment
with the apertures of the major side walls; a coil of
wire positioned between and bounding the apertures in
the reel flanges; and, extending between parts of the
reel flanges bounding said aligned apertures and secured
with respect to the reel flanges, a substantially rigid
hollow hub of metal or metal alloy so secured to the
reel flanges that each reel flange is restrained against.
movement in a direction away from the adjacent major
side wall.
Since the reel flanges constitute component parts
of the coil package and serve to strengthen its major
side walls, the improved coil package has the important
advantage that the carton can be formed of a cardboard
or plastics material o~ a thickness such that it can be
readily folded.
4.
The rigid hollow hùb preferably is secured to the
major side walls in such a way that each reel flange is
locked with respect to the rigid hollow hub and is
detachably secured to the adjacent major side wall.
The aperture in each major side wall preferably is
formed from an area of weakness de~ined by a plurality
of radially extending petals which are ~olded inwardly
of the carton and are gripped between the rigid hollow
hub and the boundary wall of the aperture in the
adjacent reel flange. In this case, preferably the
hollow hub is a transversely folded strip of metal or
metal alloy, the inwardly folded petals from the
apertures in the major side walls serving to prevent
overlapping longitudinally extending edges of the
transversely folded metal strip from damaging the inner
or layer or layers of wire of the coil.
End parts o~ the rigid hollow hub may protrude
through the apertures in the reel ~langes and be so
distorted that their extreme edges bite into the outer
faces of the reel flanges. In this case, pre~erably the
apertures in the major side walls are o~ greater
diameter than the apertures in the reel flanges and end
parts of the rigid hollow hub protruding through the
apertures in the reel ~langes are so rolled radially
outwardly or are otherwise so distorted that their
extreme edges bite into the outer faces of those parts
7 ~ Aq~
5.
of the reel flanges surrounded by the boundary edges of
the apertures in the major side walls and that no part
of the hub protrudes beyond the planes contaLning the
outer races Or the major side walls.
To provide Por ready removal oP the reel Prom the
carton, the carton may have, at one Or its ends and
integral with at least one o~ the major side walls, a
foldable flap by which the carton can be opened and
closed. Alternatively, the carton may have, extending
diametrically across each major side wall and across
diametrically opposed parts Or the outer peripheral
wall, a perforated boundary line by means Or which the
carton can be readily separated into two parts which,
when moved apart in a direction transverse to the axis
15 Or the reel, permit removal of the reel and ~hich can be
reassembled about the reel.
In all cases, preferably the major side walls of
the carton are each o~ substantially rectangular shape
and have minor side walls integral with three pairs Or
20 oppositely disposed side edges oP the major side walls
and a minor side wall integral with one or each side
edge of a fourth pair Or oppositely disposed side edges
of the ma~or side walls, the latter minor side wall or
walls constituting a foldable ~lap or ~laps.
For reasons that will be explained, preferably the
carton has integral with end edges of oppositely
6. .
disposed minor side walls of the carton, ears which can
be so folded inwardly as to extend between and bear
against the reel flanges.
Preferably, the coil of wire is so positioned
between the reel flanges that the radially outer end of
the coiled wire i9 adjacent the foldable flap or flaps
of the carton.
The Invention also includes an improved method of
assembling a coil package which comprises folding at
least one blank of cardboard or plastics material to
form a closable carton comprising a pair of oppositely
disposed ~ajor side walls each having an aperture, or an
area of weakness for forming an aperture, in
substantially axial alignment with the aperture or arèa
of weakness of the other major side wall and positioning
adjacent to the inner faces of the major side walls a
pair of separately formed substantially flat reel
flanges, each having a substantially central aperture,
in such a way that the apertures of the flanges and of
the major side walls are in substantially axial
alignment; introducing a coil of wire into the carton
until it is positioned between and bounds the apertures
in the reel flanges; introducing a substantially rigid
hollow hub of metal or metal alloy through the aperture
in one major side wall, throught the aperture in the
adjacent reel flange, through the coil of wire, through
the aperture in the other reel flange and through the
aperture in the other major side wall; and securLng the
reel flanges to the rigid hollow hub in such a way that
each reel flange is restrained against movement in a
direction away from the adjacent major side wall.
To ensure that the reel flanges do not impede
introduction of a coil of wire into the carton during
assembly of the coil package, as previously mentioned
preferably the carton has, integral with end edges of
oppositely disposed minor side walls of the carton, ears
which can be so folded inwardly as to extend between and
bear against the reel flanges to hold them apart and so
permit introduction of a coil ol wire into the carton
prior to introduction of the rigid hollow hub through
the aligned apertures.
Accordingly, the invention also includes a method
of assembling an improved coil package which comprises
folding at least one blank of cardboard or plastics
material to form a closable carton comprising a pair of
oppositely disposed major side walls each having an
aperture, or an area of weakness for forming an
aperture, in substantially axial alignment with the
aperture or area of weakness of the other ma;or side
wall, minor side walls integral with pairs o~ oppositely
disposed side edges o~ the major side walls and a minor
side wall integral with at least one side edge of
another pair o~ oppositely disposed side edges of the
major side walls, said latter minor side wall
~ ~ r~
8. j.
constituting a foldable flap for closing the carton, end
edges of one pair of oppositely disposed minor side
walls having ears integral with said minor side walls;
introducing into the carton a pair of separa~ely formed
substantially flat reel flanges, each having a
substantially central aperture, in such a way that each
is adjacent to the inner face of one of the major side
walls with its aperture in substantially axial
alignmentwith the aperture of said major side wall;
folding said ears inwardly to extend between and bear
asainst the reel flanges to hold the flanges apart;
introducing a coil of wire into the carton until it is
positioned between and bounds the apertures in the reel
flanges; introducing a substantially rigid hollow hub of
metal or metal alloy through the aperture i~ one major
side wall, through the aperture in the adjacent reel
flange, through the coil of wire, through the aperture
of the other reel flange and through the aperture in the
other major side wall; and securing the reel flanges to
the rigid hollow hub in such a way that each reel flange
is restrained against movement in a direction away from
the adjacent major side wall.
In the preferred method of assembly, the area of
weakness in each major side wall is defined by a
plurality of radially extending petals which are folded
inwardly of the carton and is surrounded by a
substantially continuous circle of perforations, the
~ f~
9. j.
rigid hollow hub i5 formed by inserting through the
aligned apertures in the major side walls and reel
flanges and through the coil, a transversely ~olded
strip of metal or metal alloy which is caused or
permitted to expand radially outwardly to grip the
inwardly extending petals of each major side wall
between the rigid hollow hub so formed and the boundary
wall of the aperture in the adjacent reel flange, and
end parts of the rigid hollow hub protruding through the
apertures in the major side walls are so rolled radially
outwardly that thelr extreme edges bite into the outer
faces of those parts of the major side walls surrounded
by the circles of perforations.
The invention is further illustrated by a
description, by way of example, of two preferred forms
of improved coil package and of the preferred method of
assembling the improved coil package, with reference to
the accompanying drawings, in which:-
Figure 1 is an isometric view of a stage in the
manufacture of the improved coil package;
Figure 2 is an isometric view of a later stage in
the manufacture of the improved coil package;
Figure 3 is a fragmental sectlonal side view of
the partly assembled coil package shown in Figure
2;
Figure 4 is an isometric ~iew of one preferred
form of the improved coil package;
10 . "
Figure 5 is an isometric view of a second
preferred form of the improved coil package, and
Figures 6 and 7 are fragmental isometric views of
the improved coil package showing the preferred
method of providing for re-closure of the carton
of the coil package.
Referring to Figure 1, in the preferred method o~
assembling the improved coil package a blank of
cardboard is folded to form a closable carton 1
comprisin~ a pair of oppositely disposed major side
walls 2 each of substantially square shape and each
having a central area of weakness~3 in axial alignment
with the area of weakness of the other major side wall~
each area of weakness comprising a plurality of radially
extending petals 4. Minor side walls 5, 6 and 7 are
integral with three pairs of oppositely disposed side
edges of the major side walls 2 and each side edge of
the fourth pair of oppositely disposed side edges of the
major side walls has an integral foldable flap 8, 9 for
closing the carton. End edges of oppositely disposed
minor side walls 5, 7 have integral with these walls
foldable ears 10.
A pair of separately formed flat reel flanges 14
each of circular shape and each having a central
aperture 15 is introduced into the carton 1 in such a
way that each reel flange is in inter-i'acial contact
with the inner face of one of the major side walls 2
11 .
with its aperture in axial alignment with the area of
weakness 3 o~ the major side wall. Ears 10 are then
folded inwardly and reciprocating deflecting means,
which are introduced through holes 12 in the minor side
walls 5, 7, cause the ears to extend between and bear
against the reel flanges 14 to hold them apart and in
inter-facial contact with the inner faces of the major
side walls 2. A coil of wire (not shown) is then
introduced into the carton through the upper open end
until it is positioned between and bounds the apertures
15 in the reel flanges 14.
Referring to Figures 2 and 3 in which, for
clarity, the coil of wire is omitted, petals 4 of each
major side wall 2 are then ~olded inwardly of the carton
1 to bear against the bour.dary walls of the apertures 15
in the reel flanges 14 and a metal strip 16 transversely
folded into tubular form with its longitudinal edges
overlapping is introduced through the resulting aperture
13 in one major side wall 2, through the aperture 15 in
the adjacent reel flange 14, through the coil of wire,
through the aperture 15 of the other reel flange 14 and
through the resulting aperture 13 in the other major
side wall 2 and the folded strip is expanded radially
outwardly to grip the petals tightly between the rigid
hollow hub 17 so formed and the boundary walls of the
apertures in the reel flanges. End parts 18 of the
rigid hollow hub 17 protruding from the apertures 13 in
12.
the major side walls 2 are then rolled radially
outwardly to such an extent that the extreme edges of
the hub bite into the outer faces of the major side
walls, the major side walls being distorted to such`a
dish-like shape that no part of the hub protrudes beyond
the planes containing the boundary edges of the carton
1. The carton 1 is then closed by ~olding flaps 8, 9
one on top of the other and sealing the carton by
adhesive tape.
Assembly of the coil package as above described is
effected automatically be mean~ of machine~ associated
with and positioned adjacent to a coil winding machine.
The fLrst preferred form of coil package shown In
Figure 4 comprises a carton 21 ~ormed from a blank of
cardboard and having a pair of oppositely disposed major
side walls 22 each of which is of square shape and has a
central aperture in axial alignment with the aperture of
the other major side wall. A pair o~ separately formed
flat reel ~langes 34, each of circular shape and having
a central aperture in axial alignment with the apertures
of major side walls 22, is in inter-facial contact with
the inner faces of the ma;or side walls and a coil 35 of
wire i9 positioned between and bounds the apertures in
the reel flanges. A rigid hollow hub 37 formed by a
transversely folded metal strip extends between the
major side walls 22, and inwardly folded petals
integral with the boundary walls of the apertures in the
13.
major side walls are tightly gripped between the hub and
the boundary walls of the apertures in the flanges 34 to
lock the ~lange~ to the hub. End parts 38 of the hub 37
are rolled radially outwardly to such an extent that the
extreme edges of the hub bite into the outer faces o~
the major side walls 22.
Each major side wall 22 has a circle 36 o~
perforations which is co-axial with and radially
outwardly of the distorted end part 38 o~ the hub 37 to
facilitate separation ot' the reel Planges 34 ~rom the
major side walls when it is required to withdraw the
reel from the carton. At each o~ two diametrically
opposed positions around the per~orated circle 36 are a
pair of holes 41 bounding between them a tab 42 which is
not perforàted. The tabs 42 ensure that the integrity
of the improved coil package is not accidentally broken
and, when the reel is to be removed ~rom the carton 21,
separation of each reel flange 34 from the major side
wall 22 by tearing around the circle 36 o~ per~orations
can be completed by inserting a sharp instrument, such
as a kni~e blade or screw driver, into one hole 41 of
each pair of holes and cutting through the tab 42.
Figure 5 shows an isometric view of a second
pre~erred ~orm of coil package which is substantially
identical to the coil package illustrated in Figure 4
except that the circle 36 o~ per~orations in each major
side wall 22 surrounding the distorted end o~ the hub 37
14.
has no circumferentially spaced positions where the
major side wall is not per~orated. Minor side wall 25
has extending part way along each o~ its boundaries with
the major side walls 22 a row of per~orations by means
of which a lea~ 43 can be folded out of the wall. By
unwinding wire from the coil 35 in the direction shown
by the arrow to cause the reel to rotate, the parts of
the major side walls 22 to which the protruding ends 38
of the hùb 37 are secured can be caused to separate ~rom
the other parts o~ the major side walls along the
circles 36 o~ per~orations.
As will be seen on referring to Figures 6 and 7,
to provide ~or temporary closure of the carton 21 after
partial use of wire from the coil 35 has taken place,
one edge of flap 28 has a recess 48 whose width
increases smoothly in a direction away ~rom that edge
and the corresponding edge of the other flap 29 has a
tab 49 defined by two slits 40 which converge in a
direction away ~rom that edge, thereby enabling one flap
to overlie and detachably engage the other ~lap.
