Other

Sonoco Development Incorporated

Mossberg Industries, Inc.

C Robert Ripplinger

Jacob F Ripplinger

A flange design providing improved strength, fracture resistance, and the like using corrugations extending substantially radially from an arbot aperture toward a rim portion. A spool or reel may include a tubular member to receive a stranded material wrapped therearound. A first flange comprising a core portion and an outer portion may secure to one end of the first flange engaging the tubular member. A second flange may secure to the other end of the tubular member. The core portion of a flange may comprise an arbor wall defining the perimeter of an arbor aperture. The arbor wall may be directly contacted and supported by a plurality of corrugations extending radially therefrom. The outer prortion of a flange may contact the core portion and extending radially away therefrom to an outer edge to restrain the stranded material in an axial direction.

Method of forming a reel having corrugated flanges

A flange design providing improved strength, fracture resistance, and the like using corrugations extending substantially radially from an arbor aperture toward a rim portion. A spool or reel may include a tubular member to receive a stranded material wrapped therearound. A first flange comprising a core portion and an outer portion may secure to one end of the first flange engaging the tubular member. A second flange may secure to the other end of the tubular member. The core portion of a flange may comprise an arbor wall defining the perimeter of an arbor aperture. The arbor wall may be directly contacted and supported by a plurality of corrugations extending radially therefrom. The outer portion of a flange may contact the core portion and extending radially away therefrom to an outer edge to restrain the stranded material in an axial direction.

Corrugated flanges for spools and reels

A method for welding parts formed of polymeric resins having different melt-index grades. The method may include the steps of selecting a tube formed of a first thermoplastic in an extrusion process, selecting a first flange formed of a second thermoplastic in an injection molding process and having a containment region sized to receive an end of the tube, inserting an end of the tube within the containment region of the first flange, and welding the tube to the flange by inducing relative rotation between the flange and the tube. The containment region may have a depth more than two times the wall thickness of the tube. Moreover, the containment region may maintain its shape and support friction pressure on a significant portion of melted material within the weld zone, so the material may continue to generate heat and conduct the same to the less easily melted material.

Cross-grade spin welding apparatus and method

Corrugated-core flanges for spools and reels

A flange design for spools and reels may be provided from molded materials such as plastics. Improved strength, stiffness, fracture resistance, energy absorption, and toughness may be provided by appropriate design of corrugations extending substantially radially from a hub or core portion toward a rim portion. Spools and reels may be produced from Styrene plastics, olefinics such as polyethylene and polyprophelene, and may have tubes formed from the same or different materials. Flanges may be designed to crush near a rim or to be stiff near a rim. Likewise, portions of a flange may be designed to buckle, fracture, or otherwise fail sufficiently to absorb energy, while protecting a spool from excessive fracture or distortion. Likewise, portions of the flange may be designed to fail while others nearby do not, in order to protect against catastrophic failure (e.g. extensive separation). Thus, whether a tube is integrally formed with a flange or attached to a flange by fasteners or bonding, the impact load typically tested by drop testing a loaded flange (wire-wrapped flange) may be survived by designing wall thickness, corrugation dimensions, and angles to selectively balance distortion, fracture, toughness, or stiffness of various portions of a spool or reel.

Simultaneous-access surfaces for reel-flange fasteners

A flange design for spools and reels may be provided from molded materials such as plastics. Improved strength, stiffness, fracture resistance, energy absorption, and toughness may be provided by appropriate design of corrugations extending substantially radially from a hub or core portion toward a rim portion. Spools and reels may be produced from Styrene plastics, olefinics such as polyethylene and polyprophelene, and may have tubes formed from the same or different materials. Flanges may be designed to crush near a rim or to be stiff near a rim. Likewise, portions of a flange may be designed to buckle, fracture, or otherwise fail sufficiently to absorb energy, while protecting a spool from excessive fracture or distortion. Likewise, portions of the flange may be designed to fail while others nearby do not, in order to protect against catastrophic failure (e. g. extensive separation). Thus, whether a tube is integrally formed with a flange or attached to a flange by fasteners or bonding, the impact load typically tested by drop testing a loaded flange (wire-wrapped flange) may be survived by designing wall thickness, corrugation dimensions, and angles to selectively balance distortion, fracture, toughness, or stiffness of various portions of a spool or reel.

Twin sheet flanges for spools and reels

A flange design for spools and reels may be provided from molded materials such as plastics. Improved strength, stiffness, fracture resistance, energy absorption, and toughness may be provided by appropriate design of corrugations extending substantially radially from a hub or core portion toward a rim portion. Spools and reels may be produced from Styrene plastics, olefinics such as polyethylene and polyprophelene, and may have tubes formed from the same or different materials. Flanges may be designed to crush near a rim or to be stiff near a rim. Likewise, portions of a flange may be designed to buckle, fracture, or otherwise fail sufficiently to absorb energy, while protecting a spool from excessive fracture or distortion. Likewise, portions of the flange may be designed to fail while others nearby do not, in order to protect against catastrophic failure (e.g. extensive separation). Thus, whether a tube is integrally formed with a flange or attached to a flange by fasteners or bonding, the impact load typically tested by drop testing a loaded flange (wire-wrapped flange) may be survived by designing wall thicknesses, corrugation dimensions, and angles to selectively balance distortion, fracture, toughness, and stiffness of various portions of a spool or reel.

Corrugated, fracture-controlling flanges for spools and reels

A plastic spool for receiving, storing and dispensing wire and cable is formed of multiple pieces. A preferred design is assembled in two halves, each having a tube portion and a flange portion. The tube portions have stepped, mating diameters. The tube portion of one half is stepped on the inside diameter and the tube portion of the other half is stepped on the outside diameter to match. Preferably two stepped diameters are used, besides the principal inside and outside diameters which are virtually identical for each tube portion. The spool includes ribbed flanges for strength and minimum resin use. For toughness, an olefinic resin such as polyethylene or polypropylene is used for molding. The spool may be assembled in three pieces, a tube and a pair of flanges. In any embodiment, the halves or pieces are bonded together, preferably by spin welding, hot plate welding, ultrasonic welding or induction welding. In some embodiments, the pieces may be fastened mechanically. Larger spools, usually referred to as reels are configured to receive a tube into a channel formed in each flange. The channel wall extends outboard of the flange wall, permitting a penetrating fastener to secure the tube to the channel wall without making any blemish or bump which might damage wire in the wrapping region around the tube between the flanges.

Mating spool assemblies for relieving stress concentrations

A plastic spool for receiving, storing and dispensing wire and cable is formed of multiple pieces. A preferred design is assembled in two halves, each having a tube portion and a flange portion. The tube portions have stepped, mating diameters. The tube portion of one half is stepped on the inside diameter and the tube portion of the other half is stepped on the outside diameter to match. The spool may be assembled in three pieces. The halves or pieces may be bonded together, such as by spin welding, hot plate welding, ultrasonic welding or induction welding. In some embodiments, the pieces may be fastened mechanically. Larger spools, usually referred to as reels may be configured to receive a tube into a channel formed in each flange. The channel wall may extend outboard of the inside flange wall, permitting a penetrating fastener to secure the tube to the channel wall without making any blemish or bump which might damage wire in the wrapping region around the tube between the flanges.

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Millville, UT, United States of America

C Robert Ripplinger