Single-step molded reel

Abstract

A reel, alternately called a spool, may be manufactured in a fully assembled, single, homogeneously molded piece. Processes may include injection molding, blow molding, and other suitable molding processes adapted to polymeric resins. The apparatus and method are well adapted to manufacturing processes using olefinic resins, such as polypropylene and polyethylene. The resulting reel or spool may serve as a take-up reel for receiving, storing, transporting, and dispensing stranded materials wound thereon. The barrel may fit within a cylindrical envelope extending between hub portions of flanges disposed at opposite ends. An arbor hole extends along the longitudinal axis of rotation for supporting the reel. Flanges extend radially from the barrel, substantially orthogonally thereto, on a smooth, inside face of each flange. Flanges may be tapered, ribbed, and so forth in order to obtain proper stiffness with minimum weight, while still remaining moldable in a single process not requiring post-molding assembly. Apertures serving as drive holes for a drive pin, start holes for stranded (e.g. wire) material, and tie holes may be provided by pins of sufficiently small dimension to not interfere with hydraulic and cooling channels in the molds. Certain methods may use large core pulls, but certain embodiments may be made from two piece molds having 'pull pins' only for the arbor hold and the aforementioned apertures. Tooling slides may be used but are not required.