Note: Descriptions are shown in the official language in which they were submitted.
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Title: Collapsible Reel and Method of Assembly
FIELD OF THE INVENTION
The present invention relates to a collapsible reel for shipping
and storage of flexible cables, pipes, and other elongate articles, and to a
method of assembly of such a reel.
BACKGROUND OF THE INVENTION
Various designs for reels which may be used for shipping and
storage of flexible cables, pipes, and other elongate articles, and which may
be collapsed for storage and assembled for reuse, are known in the art.
One example is U.S. Patent No. 4,620,676 issued to Missalla
which discloses a dismountable reel having two circular side members
with inside and outside faces. The circular side members have attachment
rings on the inside faces of the side members, with openings around the
attachment rings. A core member is formed from a strip of sheet metal,
the strip having junctions at the ends so that the strip may be formed into
a generally cylindrical shape, and attachment tongues on the edges of the
strip are interengagable with the attachment rings. While this design
provides a functional collapsible reel, the wire rod structure forming the
circular side members may be time consuming to manufacture, likely
requiring extensive soldering. Also, the solid core member, while
functional, would add significantly to the weight of the reel.
Other reel designs propose solid side members including U.S.
Patent No. 5,806,788 issued to Witwer et al.; U.S. Patent No. 5,588,628
issued to Sachleben; and U.S. Patent No. 4,066,224 issued to Hargreaves et
al. While such solid side wall designs provide strength, again the
additional material likely adds significantly to the weight of the reels.
Yet another example is U.S. Patent No. 5,242,129 issued to Bailey
et al., which discloses a knockdown cable reel including a central drum
with radially extending flanges positioned on each end to form circular
side members. The flanges are formed from a plurality of segments to
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facilitate assembly and disassembly. A flange ring encircles the outer
periphery of each flange to stabilize the flange during use. Again, the
amount of material used to form the solid side flanges and the solid
central drum will add weight to the cable reel. Furthermore, because the
central drum is not collapsible, the central drum will still occupy
significant space when the reel is knocked down.
OBJECTS OF THE INVENTION
With the foregoing in mind, a primary objective of the present
invention is to provide a relatively light weight reel assembly which is
inexpensively manufactured and which is readily collapsible for storage
and which is readily assembled for reuse.
Another objective of the present invention is to provide a reel
assembly in which the diameter of the cylindrical structure between the
side wall members may be adjusted to one of a number of possible
diameters so as to increase or decrease the capacity of the reel.
A further object of the present invention is to provide a method
of manufacturing side wall members and forming a central cylindrical
structure for a reel quickly and inexpensively.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a reel for
winding flexible cables, pipes and the like, comprising:
a) a pair of side wall members, each side wall member having:
i) a center hub connector, the center hub connector being
formed from an annular axle sleeve having a plurality
of plugs distributed around and extending radially
outwardly from the outer surface of the annular axle
sleeve, the plugs lying in a common plane;
ii) a plurality of spokes having a cavity at an inner end for
receiving one of the plugs therein, the spokes lying in
the plane and extending radially outwardly;
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iii) an outer rim, the rim securely connecting an outer end
of the spokes, the rim lying in the plane; and
b) a transverse generally cylindrical structure formed between
the pair of side wall members, the generally cylindrical
structure causing the pair of sidewall members to be
substantially parallel and axially aligned along the axis of
rotation of the reel.
In an alternative embodiment, the spokes may comprise a
plurality of pairs of adjacently fixed spokes formed from the ends of a
continuous, bent, elongate member which substantially defines a sector of
a circle.
Preferably, the cavities in each of the spokes have a cross-section
substantially matching the cross-section of the plugs, whereby the plugs
closely fit inside the cavities.
Optionally, the side walls of the plugs are tapered and the cross-
section of the plugs progressively broadens towards the base of the plugs,
whereby the plugs tightly fit in the cavities when the spokes are driven
down onto the plugs.
In one embodiment, the spokes are crimped onto the plugs, so as
to lock the spokes onto the plugs.
Advantageously, the rim of the reel is formed from an
appropriate length of a U-shaped channel curved substantially into a
broken ring, the opening of the U-shaped channel facing radially inward,
the rim being flexible so as to allow the rim to be enlarged to receive all of
the outer ends of the spokes within the U-shaped channel, the parallel side
portions near the outer ends of the spokes closely fitting between the side
walls of the U-shaped channel, the rim then being closeable to form an
unbroken ring.
Preferably, the outer rim is crimped to the outer ends of the
spokes so as to lock the spokes in position.
In a preferred embodiment, the transverse generally cylindrical
structure comprises a plurality of transverse bars mounted between a pair
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of correspondingly aligned spokes of each of the side wall members, the
bars being mounted at generally the same radial distance from the center
of each of the side wall members.
Advantageously, the radial distance from the center of the side
wall members to the transverse bars is adjustable, whereby the diameter of
the transverse generally cylindrical structure may be adjusted, so as to
adjust the capacity of the reel.
More advantageously, radial distance margins are provided on
the spokes so as to facilitate even adjustment of the transverse bars.
In another aspect, the present invention provides a method of
assembling a reel, the method comprising the steps of:
a) providing a center hub connector, the center hub connector
being formed from an annular axle sleeve having a
plurality of plugs distributed around and extending radially
outwardly from the outer surface of the annular axle sleeve,
the plugs lying in a common plane;
b) providing a plurality of spokes having a cavity at one end
for receiving one of the plugs therein, the spokes lying in
the plane and extending radially outwardly;
c) providing an outer rim for connecting an outer end of each
of the spokes, the rim being formed from an appropriate
length of an U-shaped channel;
d) inserting the plugs into the cavities to connect the spokes to
the center hub connector and connecting the outer end of
the spokes to the outer rim to form a sidewall member; and
e) providing a plurality of transverse bars and mounting each
of the transverse bars between a pair of correspondingly
aligned spokes of each of a pair of the sidewall members,
the transverse bars forming a transverse generally
cylindrical structure between the side wall members, the
generally cylindrical structure causing the pair of side wall
members to be substantially parallel and axially aligned
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along the axis of rotation of the reel.
Preferably, the method further comprises the step of crimping
the spokes over the plugs so as to lock the spokes in position.
More preferably, the method further comprises the step of
mounting the transverse bars to the spokes using adjustable U-bolts.
In another aspect, the present invention provides an apparatus
for assembling a side wall member, the apparatus comprising:
a) a platform having a defined center position for receiving a
center hub connector having plugs;
b) a center crimping tool assembly mounted to the platform at
the defined central position, the central crimping tool
assembly providing means for crimping an inner end of a
spoke onto each of the plugs;
c) a plurality of telescopic arms mounted to the platform and
extending radially outwardly from the defined central
position, the length of the telescopic arms being adjustable
to receive different sizes of the spokes; and
d) a plurality of outer rim crimping tool assemblies, each outer
rim crimping tool assembly being mounted at an outer end
of each telescopic arm, and receiving an outer end of the
spokes together with a portion of an outer rim, the outer
rim crimping tool providing means for crimping the outer
ends of the spokes into the outer rim, the number of outer
crimping tool assemblies corresponding to the number of
rim-spoke connection points in the side wall member.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A shows a plan view of a first embodiment of a side wall
member in accordance with the present invention;
Figure 1B shows a plan view of a second embodiment of a
sidewall member in accordance with the present invention;
Figure 2A shows a plan view of a center hub connector for the
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side wall member of Figure 1A; '
Figure 2B shows a side view of the center hub connector of
Figure 2A;
Figure 2C shows an enlarged view of a tapered plug for the
center hub connector of Figures 2A and 2B;
Figure 2D shows a first embodiment of a pair of separate spokes
for the side wall member of Figure 1A;
Figure 2E shows a second embodiment of a pair of spokes which
are formed from the ends of a continuous, bent member;
Figure 2F shows a third embodiment of a pair of separate spokes
having bent outer ends;
Figure 3A shows an enlarged partially hidden plan view of a
joint connection, between an outer rim and an outer edge of a spoke, on
the side wall member of Figure lA;
Figure 3B shows a length of U-shaped channel curved
substantially into a ring for the side wall member of Figure lA;
Figure 3C shows a cross-sectional view of the joint connection in
Figure 3A, taken along the line A--A of Figure 3A;
Figure 4 shows a top view of an assembly apparatus for
assembling the side wall member of Figure 1A;
Figure 5A shows a partially hidden front view of one of the
outer rim crimping tools shown in Figure 4;
Figure 5B shows a bottom view of the outer rim crimping tool of
Figure 5A;
Figure 5C shows a side view of the outer rim crimping tool
of Figure 5A;
Figure 6 shows a side view of a telescopic tool support arm for
supporting the outer rim crimping tool of Figures 5A-5C;
Figure 7A shows an enlarged top view of the center hub
connector crimping tool shown in Figure 4, together with a center hub
connector and spokes for the side wall member of Figure 1;
Figure 7B shows the same components as in Figure 7A but with
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the center hub connector and spokes rotated clockwise into position for
crimping;
Figure 8A shows a side view of the center hub bottom crimping
tool assembly mounted onto a platform, for assembling the side wall
member of Figure 1A;
Figure 8B shows an enlarged view of the center hub bottom
crimping tool assembly of Figure 8A;
Figure 9A shows a detailed bottom view of a center hub bottom
crimping die retaining plate assembly, for assembling the side wall
member of Figure 1A;
Figure 9B shows a side view of the assembly of Figure 9A;
Figure 10A shows a transverse bar mounted between two
correspondingly aligned spokes of a pair of side wall members;
Figure 10B shows a transverse bar inserted into an optional
receptacle mounted onto each spoke;
Figure lOC is a top view of the assembly shown in Figure 10B;
Figure 10D is an end view of the assembly shown in Figure lOB;
Figure 10E shows a plan view of one embodiment of a receptacle
which receives one end of a transverse bar;
Figure 10F shows a plan view of optional divider bars which are
adjustably mounted onto a transverse bar;
Figure lOG shows a bottom view of the assembly shown in
Figure lOF;
Figure 10H shows a detailed plan view of the mounting portion
of the divider bar;
Figure 10I shows a bottom view of the mounting portion of the
divider bar shown in Figure lOF;
Figure 11A shows an exploded view of one embodiment of the
reel of the present invention; and
Figure 11B shows an exploded isometric view of another
embodiment of the reel of the present invention.
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DETAILED DESCRIPTION OF THE INVENTION
Referring to Figure 1A, a first embodiment of a side wall
member 1 of the present invention is shown. Each side wall member
comprises a center hub connector 10 connecting a plurality of spokes 20 at
their inner ends 21 and an outer rim 30 connecting the spokes 20 at their
outer ends 22.
Now referring to Figure 1B, another embodiment of a side wall
member 1 of the present invention is shown. Each side wall member 1
comprises a center connector 11 connecting a plurality of spokes 20b at
their inner ends 21 and an outer rim 30b connecting the spokes 20b at their
outer ends 22b. In Figure 1B each of the spokes 20b are welded at their
inner ends 21 to a plate 11a. Advantageously, the outer ends 22b of each of
the spokes 20b are bent at their outer ends 22b to allow for a filler joint
weld between the outer ends 22b and the outer rim 30b. This detail is
illustrated in Figure 1C. It will be appreciated that the center hub
connector 10 of Figure 1A may be used instead of the center connector 11
shown in Figure 1B and vice versa. Various other embodiments for the
side wall member 1 are possible but each embodiment should include a
plurality of spokes extending radially outwardly from a center.
Now referring to Figure 2A, an enlarged plan view of the center
hub connector 10 of Figure 1 A is shown. Each center hub connector 10 is
formed from a generally annular axle sleeve 12 having a plurality of plugs
14 distributed around and extending radially outwardly from the outer
surface of the annular axle sleeve 12. As shown in Figure 2B, the plugs 14
are aligned and lie in a plane which is perpendicular to the axis of rotation
of the center hub connector 10. The plugs 14, shown by way of example in
Figures 2A and 2B, are generally elongate bars having a square cross-
section. However, it will be appreciated that the plugs can have a cross-
section of virtually any shape that facilitates mating with an appropriately
shaped cavity. For example, the cross-section of the plugs 14 may be
circular, rectangular, hexagonal, or another polygonal shape. The length
of the plugs 14 is not critical but preferably should be at least as long as
the
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width of the plugs 14 so as to provide adequate support for the spokes 20.
The plugs may be shorter than their width provided that there is still
sufficient space for crimping, as described further below.
Optionally, as shown in Figure 2C, a plug 14a may be tapered
such that its cross-section progressively broadens towards its base. This
tapered plug 14a is designed to fit tightly into an appropriately shaped
cavity at the inner end 21 of a spoke 20 when the spoke 20 is driven down
onto the plug 14a.
As shown in Figure 2D, individual spokes 20 of generally equal
length may be mounted onto the plugs 14,14a by their inner ends 21 which
have appropriately shaped cavities (not shown) to receive the plugs 14,
14a. The outer ends 22 may be connected to the rim 30 as described below.
In an alternative embodiment, as shown in Figure 2E, a pair of adjacently
fixed spokes 20a are formed from the ends of a continuous, bent, elongate
member which substantially defines a sector of a circle. The fixed spokes
20a have a common outer end 22a which is analogous to the outer end 22
of an individual spoke 20. In one possible embodiment, the outer end 22a
has substantially the same curve as the rim. Preferably, the fixed spokes
20a form substantially the same angle (angle A° in Figure 2E) as two
adjacent individual spokes 20 would when mounted onto two adjacent
plugs 14,14a (angle A° in Figure 2D). Note that the tapered plugs 14a
are
designed to make it easier to mount the inner ends 21 of the fixed spokes
20a onto adjacent plugs 14a, as the ends of the fixed spokes 20a will
approach the plugs 14a at an angle.
Now referring to Figure 2F, another embodiment of a pair of
spokes 20b is shown. The spokes 20b of Figure 2E have their outer ends
bent at substantially 90° which allow them to either fit within a rim
formed from a U-shaped channel (described below) or be welded to a rim
formed from a tube using a filler joint weld (Figure 1C). Advantageously,
a filler joint weld will provide greater strength at the spoke-rim joints.
It will be appreciated that each of the inner ends of the spokes 20,
20a, 20b may also be mounted and/or welded onto a center hub connector
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as shown in Figures 2A-2C or, alternatively, be welded to a plate lla as
shown in Figure 1B.
Now referring to Figure 3A, an enlarged partially hidden view of
a rim 30 connected to the outer end of a spoke 20 is shown. In one
5 embodiment shown in Figure 3B, the outer rim 30 is formed from an
appropriate length of a U-shaped channel curved substantially into a ring
having a break 31. As shown in Figure 3B, the opening of the U-shaped
channel is facing radially inwardly. Before the break 31 is closed, the outer
rim 30 is flexible so as to allow the diameter of the outer rim 30 to be
10 enlarged to receive all of the outer ends of the spokes 20 which are
mounted on the plugs 14,14a within the U-shaped channel of the rim 30.
As shown in Figure 3C, the outer end 22 of a spoke 20 may be secured to
the outer rim 30 by means of a crimping connection which partially
punctures the side walls of the U-shaped channel and sides of the spokes
20 so that flaps of material 25, 35 are bent inwardly. Once the connections
have been made, the break 31 can be closed so that the rim 30 is a
continuous ring. The break may be closed in any one of a number of
conventional methods, for example, by welding the break 31 together, or
by placing a bridge piece (not shown) extending between the two sides of
the break 31 and fastening the ends of the break 31 onto the bridge piece by
welding, crimping, adhesive, etc. A device for forming a connection at all
rim-spoke connection points at the same time is described further below.
For additional strength at the rim-spoke connection points, it is possible to
use adhesives or induction welding in conjunction with this type of
crimping connection. Alternatively, adhesives or welding could be used
instead of crimping.
It will be appreciated that the same type of rim-spoke connection
as described above may be formed between an outer rim 30 and the outer
end 22a of the fixed spokes 20a shown in Figure 2E. Advantageously, the
outer end 22a of the fixed spokes 20a provides additional structural
strength between the adjacent fixed spokes 20a and to the outer rim 30
since the entire outer end 22a is received within the U-shaped channel of
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the rim 30.
As discussed above, in an alternative embodiment (Figure 1B),
the rim may be formed from a metal tube which is formed into a ring of
suitable diameter for a given set of spokes 20, 20a, 20b. Preferably, the
metal tubing used to form the rim 30b has either a square or rectangular
cross-section and will allow the outer ends of spokes 20, 20a, 20b to be
securely welded to it.
Figure 4 shows a top view of the side wall member 1 of Figure 1
in an apparatus for crimping the spokes 20 onto the center hub connector
10 and for crimping the outer ends of the spokes 20 onto the outer rim 30.
As shown in Figure 4, a center hub connector crimping tool 70 shown in
dotted outline is mounted on a platform 40 which supports the center hub
connector 10. Extending radially outwardly from the platform 40 are
telescopic tool support arms 60 each of which support an outer rim
crimping tool 50. The telescopic function is described further below.
Now referring to Figures 5A-5C, an enlarged view of the outer
rim crimping tool 50 is shown. The outer rim crimping tool 50 comprises
opposing puncture dies 102t, 102b which are retained on die retaining
plates 55a, 56a. The puncture dies 102t, 102b are positioned over and
under, respectively, each rim-spoke connection point (Figure 3A) and are
urged toward each other to form a locked rim-spoke connection as shown
in Figure 3C. As illustrated in Figure 5C, the puncture dies 102 are
substantially wedge-shaped such that a puncture can be made in the outer
rim 30 and spokes 20 and flaps of material 25, 35 are bent inwards to form a
locked connection (Figure 3A and 3C). Supporting the top die retaining
plate 55a is a top plate 53. A spacer plate 52 of appropriate width to accept
a
rim 30 is positioned between the top plate 53 and a bottom plate 51 which
provides a supporting surface for the rim 30. The plates 51, 52, 53 are
secured together, for example, by bolts and nuts (not shown). The bottom
plate 51 has an orifice 51a through which the bottom puncture die 102 and
die retaining plate 56a can pass in order to urge the bottom puncture die
102 towards the top puncture die 102. The bottom die retaining plate 56a is
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fastened to the end of a hydraulic cylinder 57 which is extended for the
puncturing operation and which is withdrawn for removal of the rim 30
upon completion of the puncturing operation.
Now referring to Figure 6, a partially hidden side view of the
telescopic tool support arm 60 is shown. The telescopic tool support arm
60 comprises an outer rim crimping tool mount 62 on top of which the
outer rim crimping tool 50 is mounted. The outer rim crimping tool
mount 62 may be of tubular structure which partially overlaps with one
end of an elongate arm 64. The outer rim crimping tool mount 62 may be
adjustable relative to the elongate arm 64 over a limited distance by means
of a hydraulic cylinder 68 having one end connected to the elongate arm 64
and the other to the outer rim crimping tool mount 62. The action of the
hydraulic cylinder 68 allows the outer rim crimping tool mount 62 to
extend outwardly, in order to allow a rim 30 to be positioned in place for
connection to the spokes 20, then contract inwardly to secure the rim 30
and position the outer rim crimping tool 50 for the crimping operation,
and finally extend outwardly once more to allow the fully assembled side
wall member 1 to be removed.
Still referring to Figure 6, another end of the elongate arm 64 is
inserted into a tubular elongate arm table mount 66. Optionally, the
elongate arm 64 includes a pin hole 64a which can be aligned with one of a
plurality of pin holes 66a in the elongate arm table mount 66 and a pin
(not shown) can be placed through the aligned pin holes 64a,66a so as to
adjust the overall length of the telescopic tool support arm 60.
Alternatively, the elongate arm 64 may be adjusted relative to the elongate
arm table mount 66 by means of a hydraulic cylinder (not shown) similar
to the actin of the hydraulic cylinder 68 discussed above. This telescopic
action further accommodates side wall members 1 having various
diameters. Also shown in Figure 6 is a center hub connector 10 in position
to receive spokes 20.
Now referring to Figure 7A, a top view of a center hub connector
10 is shown with spokes 20 mounted onto plugs 14 which extend radially
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outwardly from an annular axle sleeve 12. Still referring to Figure 7A, a
center hub connector crimping tool assembly 70 is shown in dotted outline
underneath the platform 40. Mounted on top of the platform 40 are center
hub top crimping die retaining plates 72 which have an overhang portion
72a holding crimping dies 100 in position with the die tips pointed
downwards. The center hub top crimping die retaining plate 72 may be
bolted down onto the platform 40 using bolts 73 or other fastening means.
In Figure 7A, the spokes 20 are shown in between the center hub top
crimping die retaining plates 72. In this position, an operator or a machine
can mount the spokes 20 easily over the plugs 14 during the initial part of
the assembly operation.
Now referring to Figure 7B, the spokes 20 and the center hub
connector 10 are shown rotated clockwise into position, automatically or
manually, for the crimping operation. In Figure 7B, the spokes 20 now
abut the center hub top crimping die retaining plates 72 and the overhang
portion 72a positions the top crimping dies 100t directly over the spokes 20
and the plugs 14 inserted into the spoke 20.
Now referring to Figure 8A, a side view of the platform 40 is
shown with a representative center hub top crimping die retaining plate 72
mounted on top of the platform 40. For clarity, the other die retaining
plates 72 are not shown. The platform 40 may be supported by legs 42 or by
other means. Also shown in Figure 8A is the overhang portion 72a which
allows the top crimping dies 100t to be positioned over the spokes 20 and
the plugs 14 of the center hub connector 10. Furthermore, a center hub
crimping tool assembly 80 is shown mounted underneath the platform 40
by means of a hanging support base 46 which is secured to the platform 40
by means of support columns 44.
Now referring to Figure SB, an enlarged view of the center hub
bottom crimping tool assembly 70 is shown. The center hub bottom
crimping tool assembly 70 comprises a center hub bottom crimping die
retaining plate assembly 76 and a hydraulic cylinder 75 which lifts or
lowers the die retaining plate assembly 76. The die retaining plate
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assembly 76 holds bottom crimping dies 100b in position directly
underneath opposing top crimping dies 100t which are fastened to the
bottom of the overhang portion 72a of the die retaining plate 72.
Referring back to Figures 7A and 7B, once the spokes 20 and the
center hub connector 10 are automatically or manually rotated into
position, the crimping dies 100t, 100b are positioned directly above and
below the end of the spokes 20 and the plugs 14. In the position shown in
Figure 7B, the center hub bottom crimping die retaining plate assembly 86
is urged upwards by means of the hydraulic cylinder 75 to push the
crimping dies 100t, 100b into the spokes 20 and plugs 14 simultaneously
from the top and bottom, respectively. The reverse operation of the
hydraulic cylinder 75 releases the hold of the crimping dies 100t, 100b and
the spokes 20 can be automatically or manually rotated back to the position
in Figure 7A for removal of the completely assembled side wall members.
Now referring to Figures 9A and 9B, an enlarged detailed view of
the die retaining plate assembly 76 is shown. The center hub bottom
crimping die retaining plate assembly 76 includes a center hub bottom
crimping die retaining plate 76a which holds the crimping dies 100 in
position. The die retaining plate 76a may be supported by gussets 76b
which are also braced against hydraulic cylinder mounts 76c for additional
stability. Dowel guide openings 76d are shown in Figure 9A and dowel
guides (not shown) help to keep the die retaining plate assembly 76
properly aligned during a crimping operation.
While the above discussion in relation to Figures 4-7B have been
described with reference to individual spokes 20 of the type shown in
Figure 2D, it will be appreciated that, with a modification of the relative
positioning of the telescopic tool support arms 60 and the outer rim
crimping tools 50, the discussion would apply equally to the alternative
spoke arrangement (fixed spokes 20a) shown in Figure 2E above. The
modification would involve repositioning (i.e. rotating) the telescopic tool
support arms relative to the platform 40 such that the outer rim crimping
tools 50 are appropriately aligned to crimp the outer ends 22a of the fixed
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spokes 20a to the outer rim 30. Similarly, a minor modification (i.e.
repositioning of the telescopic tool support arms) may be made to
accommodate spokes 20b as shown in Figure 2F.
Now referring to Figure 10A, a transverse bar 90 is shown
fastened to correspondingly aligned spokes 20 of a pair of side wall
members 1. Preferably, the transverse bars 90 are bent at substantially
90°
at either end and these bent portions are fastened onto the corresponding
spokes 20 by means of one or more U-bolts 92, plates 33, and nuts 94. More
than one U-bolt 92 may be used per connection to provide additional
strength. The transverse bars may be of any cross-section, but are
preferably square or rectangular. Also, the bars are preferably made of
tubing so as to be relatively light weight.
Figure 10B shows the bent end of a transverse bar 90 mounted
into an optional receptacle 100. The receptacle 100 is mounted to a spoke
20. In one embodiment, the receptacle 100 is mounted to the spoke 20 by
means of a U-bolt 92, plate 93, and nuts 94. Advantageously, the U-bolt
may be loosened to reposition the receptacle 100 and then retightened to
secure the receptacle 100 in place. The receptacle 100 may be fashioned
from a short length of tubing having a cross-section corresponding to the
cross-section of the transverse bar 90 being used. In Figures lOB-10D, a
transverse bar 90 and receptacle 100 having a square cross-section are
shown. The receptacle 100 has suitable inner dimensions which allow the
bent end of the transverse bar 90 to fit snugly into the receptacle 100. Now
also referring to Figure lOC, it is shown that the bent corner 91 of a
transverse bar 90 has a tendency to deform and widen so that the bent ends
of the transverse bar 90 will fit snugly into the receptacle 100. Optionally,
the receptacle 100 has a bevelled opening 102 to better accommodate the
curved portion of the transverse bar 90. Furthermore, the receptacle 100
may be provided with an opening 104 at the opposite end of the opening
102 to allow the outermost portion of the bent end of transverse bar 90 to
extend through the receptacle 100. In use, this outermost portion of the
transverse bar 90 which extends through the receptacle 100 allows an
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operator to easily disassemble the reel by tapping out the transverse bar 90
with a hammer or similar tool.
Now referring to Figures 10F-10I, a transverse bar 90 is shown
with optional divider bars 110 mounted along its length. The divider bars
110 may be used to divide the reel into two or more segments such that
different types of flexible cables, pipes, and the like may be wound on the
same reel. The divider bars 110 have a mounting portion 112 which allow
the divider bars 110 to be adjustably mounted to a transverse bar 90. The
mounting portion 112 provides a ledge 113 which is substantially
perpendicular to the divider bar 110. This ledge 113 abuts the transverse
bar 90 and allows the divider bars 110 to be mounted to the transverse bars
90 at substantially right angles.
In one embodiment, a U-bolt 92, plate 93 and nuts 94 may be
used for mounting. In use, the divider bars 110 would be mounted so that
they extend radially outwardly from the center axis of the reel. The length
of the divider bars 110 may be selected based on the dimensions of the side
wall members 1A, 1B and the radius at which the transverse bars 90 or the
receptacle 100 are mounted to the spokes 20.
Now referring to Figure 11A, an exploded plan view of one
embodiment of a reel assembly of the present invention is shown. A
plurality of transverse bars 90 are shown between corresponding pairs of
receptacles 100 which may be adjustably mounted to corresponding pairs of
spokes 20 (not shown) of each side wall member 1. Advantageously, the
receptacles 100 may be pre-mounted onto the spokes 20 of each side wall
member 1 so that the only step required to assemble the reel is to insert
each bent end of the transverse bars 90 into corresponding pairs of
receptacles 100. Furthermore, once flexible cables, pipes, and the like have
been unwound from the reel, the reel can be easily knocked down by
removing the transverse bars 90 from the receptacles 100. As discussed
previously, removal may be facilitated by providing an open bottom end
104 to each receptacle 100 so that the transverse bar 90 may be tapped out
using a hammer or similar tool.
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Now also referring to Figure 11B, when the transverse bars 90 or
receptacles 100 are fastened to the spokes 20 at substantially the same
radius R from the axial centers of the side wall members 1, a transverse
generally cylindrical structure is formed by the transverse bars 90. The
cylindrical structure causes the pair of side wall members to be
substantially parallel and axially aligned along the axis of rotation of the
reel.
The radial distance R of the transverse bar 90 or receptacle 100
from the axial center of the side wall members may be adjusted by
loosening the U-bolts 92, plates 93, and nuts 94, aligning the transverse
bars 90 to a new radial distance R' (not shown), and then retightening the
U-bolts 92, plates 93, and nuts 94. Optional radial distance markings 93 are
provided on the spokes 20 to facilitate even adjustment of the transverse
bars 90 or receptacles 100 (Figure 10). It will be appreciated that this
adjustment may increase or decrease the capacity of the reel which is
formed. Advantageously, this adjustment allows cables or pipes which are
less flexible to be wound around a generally cylindrical structure which
has a larger diameter such that the bending stress put on the cable or pipe
is reduced. Alternatively, the capacity of the reel may be increased when
the cable or pipe to be wound on the reel can withstand a tighter bend.
The foregoing is a description of various embodiments of the
invention which are provided by way of example. It will be appreciated
that the invention is not limited to any of the specific features as
described,
but comprehends all variations which come within the scope of the
appended claims.
