U.S. patent application number 11/460569 was filed with the patent office on 2008-01-31 for modular reel assembly.
This patent application is currently assigned to Alemite LLC. Invention is credited to Erik Leonard, William P. Sumner.
Application Number | 20080023579 11/460569 |
Document ID | / |
Family ID | 38982021 |
Filed Date | 2008-01-31 |
United States Patent
Application |
20080023579 |
Kind Code |
A1 |
Leonard; Erik ; et
al. |
January 31, 2008 |
MODULAR REEL ASSEMBLY
Abstract
A modular reel assembly for winding, dispensing, transporting,
or storing hose, cord, or cable, is provided. Such a reel comprises
of a pair of substantially similar polymeric support endplates and
a pair of substantially similar polymeric spool endplates. The
substantially similar support endplates are connected by at least
one support endplate connecting member defining a predetermined
support assembly width. The substantially similar spool endplates
are connected by at least one spool endplate connecting member
defining a predetermined spool assembly width. The modular reel
assembly can thus be adjusted to particular discrete spool assembly
and support assembly widths through appropriately selected
interchangeable spool endplate and support endplate connecting
members.
Inventors: |
Leonard; Erik; (Johnson
City, TN) ; Sumner; William P.; (Kingsport,
TN) |
Correspondence
Address: |
DICKSTEIN SHAPIRO LLP
1825 EYE STREET NW
Washington
DC
20006-5403
US
|
Assignee: |
Alemite LLC
Fort mill
SC
|
Family ID: |
38982021 |
Appl. No.: |
11/460569 |
Filed: |
July 27, 2006 |
Current U.S.
Class: |
242/390.8 ;
242/401; 242/407; 242/608.4; 242/610.6 |
Current CPC
Class: |
B65H 75/22 20130101;
B65H 75/44 20130101; B65H 75/4486 20130101 |
Class at
Publication: |
242/390.8 ;
242/401; 242/407; 242/608.4; 242/610.6 |
International
Class: |
B65H 75/44 20060101
B65H075/44 |
Claims
1. A reel for winding, dispensing, transporting, or storing hose,
cord, or cable, the reel comprising: a support assembly comprising:
a pair of substantially similar opposed planar support endplates
comprised of a polymeric material; at least one first elongate
support endplate connecting member having opposed ends and
extending lengthwise between the opposed support endplates, each of
the at least one first support endplate connecting members having a
first defined support endplate connecting element disposed about
each end thereof and separated by a first predetermined support
assembly width, the first defined support endplate connecting
elements being configured to engage the opposed support endplates
such that the support endplates are separated by the first
predetermined support assembly width; and at least one second
elongate support endplate connecting member having opposed ends and
configured to be interchangeable with the at least one first
support endplate connecting member, each of the at least one second
support endplate connecting members having a second defined support
endplate connecting element disposed about each end thereof and
separated by a second predetermined support assembly width
different from the first predetermined support assembly width, the
second defined support endplate connecting elements being
configured to engage the opposed support endplates such that the
support endplates are separated by the second predetermined support
assembly width; and a spool assembly operably engaged with the
support assembly, between the support endplates thereof, such that
the spool assembly is rotatably supported by the support assembly,
the spool assembly comprising: a pair of substantially similar
opposed planar spool endplates comprised of a polymeric material;
at least one first elongate spool endplate connecting member having
opposed ends and extending lengthwise between the opposed spool
endplates, each of the at least one first spool endplate connecting
members having a first defined spool endplate connecting element
disposed about each end thereof and separated by a first
predetermined spool assembly width, the first defined spool
endplate connecting elements being configured to engage the opposed
spool endplates such that the spool endplates are separated by the
first predetermined spool assembly width and cooperate to define an
axis extending therebetween, the spool assembly being supported
along the axis by the support assembly, when the spool assembly is
operably engaged therewith, such that the spool assembly is
rotatable about the axis; and at least one second elongate spool
endplate connecting member having opposed ends and configured to be
interchangeable with the at least one first spool endplate
connecting member, each of the at least one second spool endplate
connecting members having a second defined spool endplate
connecting element disposed about each end thereof and separated by
a second predetermined spool assembly width different from the
first predetermined spool assembly width, the second defined spool
endplate connecting elements being configured to engage the opposed
spool endplates such that the spool endplates are separated by the
second predetermined spool assembly width.
2. A reel according to claim 1, wherein one of the support
endplates and spool endplates is comprised of a rotomolded
polymeric material.
3. A reel according to claim 1, wherein one of the support
endplates and spool endplates comprises a polyurethane foam
core.
4. A reel according to claim 1, wherein the connecting members are
comprised of a metallic material.
5. A reel according to claim 1, wherein the first and second
predetermined support assembly widths and the first and second
predetermined spool assembly widths are nonadjustable.
6. A reel according to claim 1, wherein the first elongate support
endplate connecting member, the second elongate support endplate
connecting member, the first elongate spool endplate connecting
member, and the second elongate spool endplate connecting member
have substantially similar cross-sections.
7. A reel according to claim 1, wherein each support endplate
defines an aperture configured to receive at least a portion of one
of the support endplate connecting elements of one of the support
endplate connecting members.
8. A reel according to claim 1, wherein at least one of the support
endplates comprises a mount configured to receive at least one of a
motor and a manual crank, the at least one of the motor and the
manual crank being configured to operably engage the spool assembly
so as to provide rotation thereof about the axis and with respect
to the support assembly.
9. A reel according to claim 1, further comprising a bearing and an
axle operably engaged between the support assembly and the spool
assembly and cooperable to allow the spool assembly to be rotatable
about the axis and with respect to the support assembly, one of the
bearing and the axle being coupled to one of the support endplates,
and the other of the bearing and the axle being coupled to one of
the spool endplates.
10. A reel according to claim 1, further comprising a guide member
operably engaged with the support assembly and adapted to guide one
of a hose, a cord, and a cable therethrough to be wound onto the
spool assembly.
11. A reel according to claim 1, further comprising: a gear mounted
to one of the spool endplates; and a drive mechanism operatively
coupled to the gear and configured to drive the spool assembly to
rotate about the axis of the spool assembly.
12. A reel according to claim 7, wherein the aperture is configured
to receive the connecting element of a connecting member, the
connecting element comprising a threaded end portion of the
connecting member, with opposing threaded end portions being
separated by an unthreaded medial portion of the connecting member
and the medial portion having a greater diameter than the end
portions, the connecting element being configured to be operably
engaged by a complementarily-threaded securing member so as to
secure the support endplate between the unthreaded medial portion
of the connecting member and the securing member.
13. A reel assembly according to claim 1, wherein one of the
support endplates and spool endplates is comprised of a molded
polymeric material, and wherein the one of the support endplates
and spool endplates comprises a tubular insert operably engaged
with and extending axially through the polymeric material, the
tubular insert being configured to receive at least a portion of
one of the support endplate and spool endplate connecting elements
of one of the support endplate and spool endplate connecting
members.
14. A method of manufacturing a reel for winding, dispensing,
transporting, or storing hose, cord, or cable, the reel comprising
a spool assembly rotatably supported by a support assembly, the
method comprising: connecting at least one first elongate support
endplate connecting member lengthwise between a pair of
substantially similar opposed planar support endplates, the support
endplates being comprised of a polymeric material, and the at least
one first elongate support endplate connecting member having
opposed ends each having a first defined support endplate
connecting element disposed thereabout so as to be separated by a
first predetermined support assembly width, the first defined
support endplate connecting elements being configured to engage the
opposed support endplates such that the support endplates are
separated by the first predetermined support assembly width, and
being interchangeable with at least one second elongate support
endplate connecting member having opposed ends each having a second
defined support endplate connecting element disposed thereabout so
as to be separated by a second predetermined support assembly width
different from the first predetermined support assembly width, the
second defined support endplate connecting elements being
configured to engage the opposed support endplates such that the
support endplates are separated by the second predetermined support
assembly width; connecting at least one first elongate spool
endplate connecting member lengthwise between a pair of
substantially similar opposed planar spool endplates, the spool
endplates being comprised of a polymeric material, and the at least
one first spool endplate connecting member having opposed ends each
having a first defined spool endplate connecting element disposed
thereabout so as to be separated by a first predetermined spool
assembly width, the first defined spool endplate connecting
elements being configured to engage the opposed spool endplates
such that the spool endplates are separated by the first
predetermined spool assembly width, and being interchangeable with
at least one second elongate spool endplate connecting member
having opposed ends each having a second defined spool endplate
connecting element disposed thereabout so as to be separated by a
second predetermined spool assembly width different from the first
predetermined spool assembly width, the second defined spool
endplate connecting elements being configured to engage the opposed
spool endplates such that the spool endplates are separated by the
second predetermined spool assembly width, the at least one first
and second spool endplate connecting members each being configured
to connect the opposed spool endplates such that the spool
endplates cooperate to define an axis extending therebetween; and
operably engaging the spool assembly with the support assembly such
that the spool assembly is supported along the axis by the support
assembly and is rotatable about the axis.
15. A method according to claim 14 further comprising forming at
least one of the support endplates and the spool endplates from the
polymeric material using a rotomolding process about a polyurethane
foam core.
Description
FIELD OF THE INVENTION
[0001] Embodiments of the present invention relate to reels and,
more particularly, to a modular reel assembly for winding,
dispensing, transporting, or storing hose, cord, or cable.
BACKGROUND OF THE INVENTION
[0002] Long elongate flexible items such as hose, cord, or cable
are often stored on a reel. Such reels typically include a spool
portion supported by a support structure. The spool portion is
typically configured to be rotated relative to the support
structure in order to take up or dispense the hose, cord, or cable,
which is wound around the spool portion of the reel.
[0003] Such reels can be used in many different industries and
environments, and for many different applications. For example,
reels are used often in the landscaping industry for hoses used for
water or chemical treatment, in the lubrication industry for hoses
used for dispensing lubricants, or in the utility industry for
cable. Reels for holding hose, cord, or cable may be configured to
be mounted on a wall, on the floor, on the ceiling, or on a cart,
trailer, or other vehicle. Reels can also be found in the
landscaping, firefighting, utility, or fuel industries, typically
mounted to a vehicle. The reels may further be configured to have
one spool or multiple spools disposed adjacent to one another. Many
reels are stored outdoors or are otherwise subject to harsh or
hazardous environments. For example, reels for hoses used to
transport water or chemicals usually come into contact with the
water or chemicals, thereby possibly leading to corrosion of reel
components.
[0004] In some instances, reels may be constructed of steel or
another metal. The metallic components of the reel may be painted
or otherwise coated to provide protection from water or harmful
chemicals, to make the reel more esthetically pleasing, or to
provide a warning that the reel may hold a hose or cable containing
harmful chemicals, gases, or electricity. However, due to the
service environment or the particular use of the reel, the coating
may chip or peel, thereby exposing the metallic components to the
environment and leading to corrosion or other degradation. Reels
having metallic components may also be heavy, which may not be
desirable if the reel is intended to be portable or is intended to
be mounted on a wall, ceiling, or vehicle.
[0005] In some instances, reels may be configured for a specific
application and, as such, are usually not readily adaptable to
other applications. Furthermore, a manufacturer may only offer a
few different size or capacity reels which may also be less than
desirable from a flexibility standpoint, since the appropriate reel
size depends, for example, on the length, diameter, and/or
flexibility of the hose, cord, or cable, which all may vary greatly
from application to application. In some instance, the reel may
have an application-specific support structure and, thus, may not
be flexible with respect to the size or configuration of the
support structure to meet other applications. For example, if the
reel includes a motor for rotatably driving the spool, the location
of the motor is usually fixed, which may be a problem for the user
depending on the space constraints dictated by where the user wants
to mount the reel.
[0006] Thus, there exists a need for a reel that is durable,
lightweight, and readily adaptable to various applications, but
also economical and easily assembled. Such a reel should desirably
be configured to allow for flexibility and/or customization as to
size (of the support structure and/or spool capacity),
configuration, color, mounting requirements, and spool rotatability
configurations. Such a reel should also desirably be suitable for
use in harsh environments where moisture and/or hazardous chemicals
may be present.
BRIEF SUMMARY OF THE INVENTION
[0007] The above and other needs are met by the present invention
which, according to one aspect, provides a reel for winding,
dispensing, transporting, or storing hose, cord, or cable. Such a
reel comprises a support assembly including a pair of substantially
similar opposed planar support endplates comprised of a polymeric
material. At least one first elongate support endplate connecting
member having opposed ends extends lengthwise between the opposed
support endplates. Each of the at least one first support endplate
connecting members has a first defined support endplate connecting
element disposed about each end thereof and separated by a first
predetermined support assembly width. The first defined support
endplate connecting elements are configured to engage the opposed
support endplates such that the support endplates are separated by
the first predetermined support assembly width. At least one second
elongate support endplate connecting member having opposed ends is
configured to be interchangeable with the at least one first
support endplate connecting member. Each of the at least one second
support endplate connecting members has a second defined support
endplate connecting element disposed about each end thereof and
separated by a second predetermined support assembly width,
different from the first predetermined support assembly width. The
second defined support endplate connecting elements are configured
to engage the opposed support endplates such that the support
endplates are separated by the second predetermined support
assembly width. A spool assembly is operably engaged with the
support assembly, between the support endplates thereof, such that
the spool assembly is rotatably supported by the support assembly.
Such a spool assembly comprises a pair of substantially similar
opposed planar spool endplates comprised of a polymeric material.
At least one first elongate spool endplate connecting member having
opposed ends extends lengthwise between the opposed spool
endplates. Each of the at least one first spool endplate connecting
members has a first defined spool endplate connecting element
disposed about each end thereof and separated by a first
predetermined spool assembly width. The first defined spool
endplate connecting elements are configured to engage the opposed
spool endplates such that the spool endplates are separated by the
first predetermined spool assembly width and cooperate to define an
axis extending therebetween. The spool assembly is supported along
the axis by the support assembly, when the spool assembly is
operably engaged therewith, such that the spool assembly is
rotatable about the axis. At least one second elongate spool
endplate connecting member having opposed ends is configured to be
interchangeable with the at least one first spool endplate
connecting member. Each of the at least one second spool endplate
connecting members has a second defined spool endplate connecting
element disposed about each end thereof and separated by a second
predetermined spool assembly width, different from the first
predetermined spool assembly width. The second defined spool
endplate connecting elements are configured to engage the opposed
spool endplates such that the spool endplates are separated by the
second predetermined spool assembly width.
[0008] Another aspect of the present invention provides a method of
manufacturing a reel for winding, dispensing, transporting, or
storing hose, cord, or cable, wherein the reel comprises a spool
assembly rotatably supported by a support assembly. Such a method
comprises connecting at least one first elongate support endplate
connecting member lengthwise between a pair of substantially
similar opposed planar support endplates, wherein the support
endplates are comprised of a polymeric material. The at least one
first elongate support endplate connecting member has opposed ends,
each having a first defined support endplate connecting element
disposed thereabout so as to be separated by a first predetermined
support assembly width. The first defined support endplate
connecting elements are configured to engage the opposed support
endplates such that the support endplates are separated by the
first predetermined support assembly width, and are interchangeable
with at least one second elongate support endplate connecting
member having opposed ends, each having a second defined support
endplate connecting element disposed thereabout so as to be
separated by a second predetermined support assembly width,
different from the first predetermined support assembly width. The
second defined support endplate connecting elements are configured
to engage the opposed support endplates such that the support
endplates are separated by the second predetermined support
assembly width. At least one first elongate spool endplate
connecting member is connected lengthwise between a pair of
substantially similar opposed planar spool endplates, wherein the
spool endplates are comprised of a polymeric material. The at least
one first spool endplate connecting member has opposed ends each
having a first defined spool endplate connecting element disposed
thereabout so as to be separated by a first predetermined spool
assembly width. The first defined spool endplate connecting
elements are configured to engage the opposed spool endplates such
that the spool endplates are separated by the first predetermined
spool assembly width, and are interchangeable with at least one
second elongate spool endplate connecting member having opposed
ends, each having a second defined spool endplate connecting
element disposed thereabout so as to be separated by a second
predetermined spool assembly width, different from the first
predetermined spool assembly width. The second defined spool
endplate connecting elements are configured to engage the opposed
spool endplates such that the spool endplates are separated by the
second predetermined spool assembly width. The at least one first
and second spool endplate connecting members are each configured to
connect the opposed spool endplates such that the spool endplates
cooperate to define an axis extending therebetween. The spool
assembly is then operably engaged with the support assembly such
that the spool assembly is supported along the axis by the support
assembly and is rotatable about the axis.
[0009] Accordingly, embodiments of the present invention provide
significant advantages, as discussed herein in further detail.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0010] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0011] FIGS. 1a and 1b are perspective views of a reel according to
one embodiment of the present invention;
[0012] FIG. 2a is a perspective view of a support assembly
according to one embodiment of the present invention;
[0013] FIG. 2b is a perspective view of a support endplate
according to one embodiment of the present invention;
[0014] FIG. 3a is a perspective view of a spool assembly according
to one embodiment of the present invention;
[0015] FIG. 3b is a perspective view of a spool endplate according
to one embodiment of the present invention;
[0016] FIG. 4a is a perspective view of an endplate connecting
member according to one embodiment of the present invention;
[0017] FIGS. 4b and 4c are perspective views of a securing member
configured to cooperate with an endplate connecting member
according to one embodiment of the present invention;
[0018] FIG. 4d is a cross-sectional view illustrating a connection
between a support endplate and two support endplate connecting
members using two securing members, according to one embodiment of
the present invention;
[0019] FIG. 4e is a perspective view of one embodiment of the
support assembly utilizing one embodiment of the support endplate
connecting members and one embodiment of the securing members;
[0020] FIG. 5a is a perspective view of a support endplate having
tubular inserts, according to one embodiment of the present
invention; and
[0021] FIG. 5b is a cross-sectional view illustrating a connection
between a support endplate and two support endplate connecting
members using two securing members and two tubular inserts,
according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments of the inventions are shown. Indeed,
these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0023] FIGS. 1a and 1b are perspective views of a reel 1 according
to one embodiment of the present invention, comprising a support
assembly 110 and a spool assembly 10. The support assembly 110 is
configured to support the spool assembly 10 so that the spool
assembly 10 may rotate relative to the support assembly 110. Such a
configuration allows the spool assembly 10 to wind or dispense a
hose, cord, or cable (not shown). One skilled in the art will
appreciate that the terms "hose," "cords," or "cable," as used
herein refer to any flexible elongate item suited to be wound or
stored on a reel. Such a flexible elongate item may be, for
example, a tubular hose, such as a round or flat hose for
transporting a gas or liquid; electrical cable; rope; yarn; string;
continuous sheet-like material; steel cable; chain; or the like.
Similarly, references herein to a "reel" or a "hose reel" refer to
a reel apparatus for winding, dispensing, transporting, and/or
storing any such flexible elongate member as disclosed herein.
[0024] The support assembly 110 comprises two opposing support
endplates 120 connected by elongate support endplate connecting
members 130. In one exemplary embodiment, the two opposing support
endplates 120 are generally planar, and are substantially similar.
That is, in some instances, a single support endplate configuration
is capable of being used as either or both of the two opposing
support endplates 120 of the support assembly 110. According to one
advantageous aspect, the single support endplate configuration is
used as both of the two opposing support endplates 120. The
elongate support endplate connecting members 130 may be, for
example, generally cylindrical and are attached at each opposing
end thereof to one of the two opposing support endplates 120. In
one embodiment, the support endplates 120 each define apertures 122
configured to receive the ends of the support endplate connecting
members 130 for connecting the support endplate connecting members
130 to the support endplates 120. The support endplate connecting
members 130 cooperate with the support endplates 120 to define a
predetermined support assembly width W.sub.1, which is defined
herein as the distance between the support endplates 120. The
support endplates 120, the support endplate connecting members 130,
and the manner in which the support endplate connecting members 130
are connected to the support endplates 120, are discussed in
greater detail herein, for example, with reference to FIGS. 2a, 2b,
and 4a-e.
[0025] The spool assembly 10 is similarly comprised of two opposing
spool endplates 20 connected by elongate spool endplate connecting
members 30. In one exemplary embodiment, the two opposing spool
endplates are generally planar, and are substantially similar. That
is, in some instances, a single spool endplate configuration is
capable of being used as either or both of the two opposing spool
endplates 20 of the spool assembly 10. According to one
advantageous aspect, the single spool endplate configuration is
used as both of the two opposing spool endplates 20. The elongate
spool endplate connecting members 30 may be, for example, generally
cylindrical and are attached at each opposing end thereof to one of
the two opposing spool endplates 20. In one embodiment, the spool
endplates 20 each define apertures 22 configured to receive the
ends of the spool endplate connecting members 30 for connecting the
spool endplate connecting members 30 to the spool endplates 20. The
spool endplate connecting members 30 cooperate with the spool
endplates 20 to define a support surface between the two spool
endplates 20 for supporting the hose, cord, or cable, and further
determine the spool assembly width W.sub.2, which is defined herein
as the distance between the spool endplates 20. The spool endplates
20, the spool endplate connecting members 30, and the manner in
which the spool endplate connecting members 30 are connected to the
spool endplates 20, are discussed in greater detail herein, for
example, with reference to FIGS. 3a, 3b, and 4a-d.
[0026] As shown in FIGS. 1a and 1b, the width of the spool assembly
10 is configured such that the spool endplates 20/spool endplate
connecting members 30 fit between the support endplates 120 of the
support assembly 110. The spool assembly 10 defines an axis
extending through the spool endplates 20, wherein the spool
assembly 10 is supported by the support assembly 110 such that the
spool assembly 10 is capable of rotating about the axis relative to
the support assembly 110. In an exemplary embodiment, as shown in
FIGS. 1a and 1b, the spool assembly 10 includes axles 40 and 41
that are each coupled to a corresponding one of the two spool
endplates 20. Each of the support endplates 120 includes a cutout
or aperture 42 for receiving a corresponding axle. In some
instances, a bearing 140 engages each axle to facilitate the
rotation of the spool assembly 10 relative to the support assembly
110. For example, the bearings 140 may be mounted to the support
endplates 120 via fasteners engaging apertures 127, disposed on
either side of a U-shaped cutout defined by the support endplates
120. One skilled in the art will appreciate, however, that the
bearings 140 may be otherwise mounted to the support endplates 120
or spool endplates 20, or that other mechanisms for rotatably
supporting the spool assembly 10 may be implemented. For example,
in one embodiment, the axles 40, 41 may be coupled to the support
endplates 120 and the bearings 140 may be coupled to the spool
endplates 20. In another embodiment, one axle may traverse the
width of the spool assembly 10, instead of using separate axles
attached to each spool endplate.
[0027] The spool assembly 10 is assembled with the support assembly
110 to form the reel 1, wherein the reel 1 may further include a
mechanism for driving the rotation of the spool assembly 10
relative to the support assembly 110. In some instances, the drive
mechanism for the reel 1 may be actuated to rotate the spool
assembly 10 in a first direction in order to wind the hose, cord,
or cable onto the spool assembly 10. The drive mechanism may also
be actuated to rotate the spool assembly 10 in a second direction,
opposite to the first direction, in order to dispense the hose,
cord, or cable that is already wound onto the spool assembly 10.
FIGS. 1a and 1b illustrate two exemplary drive mechanisms for the
reel 1: a motor driven system and a hand crank system. The reel 1
may include both drive systems or may only have one such drive
system. One skilled in the art will appreciate that the reel 1 may
also use any other suitable drive system or may not have any drive
system other than that of allowing a user to physically rotate the
spool endplates 20 directly by hand.
[0028] The motor driven system of FIG. 1a comprises an electric
motor 160 coupled to one of the support endplates 120. In one
embodiment, the motor is a hazardous duty motor suitable for use in
hazardous duty environments where volatile gases or other hazardous
fluids may be present. In some instances, the motor 160 includes a
flange 162 with apertures for mounting the motor to one of the
support endplates 120. These apertures are aligned with
corresponding apertures 124 defined by the support endplate 120 so
that a bolt, screw, or other appropriate fastener (not shown) may
be used to mount the motor 160 to the side of the support endplate
120. The motor 160 includes driveshaft (not shown) that extends
through aperture 126 in the support endplate 120. A sprocket 161 is
coupled to the driveshaft and engages a chain 65. The chain 65 also
engages a spool sprocket 60, which is coupled to a spool endplate
20, so that rotation of the driveshaft causes rotation of the spool
assembly 10. In the illustrated embodiment, the motor mount
apertures 124 and 126 of the spool endplates 120 are elongated so
that the position of the motor can be adjusted in order to fit the
chain 65 around the sprocket 161 and in order to appropriately
adjust the tension of the chain 65. In some instances, such as that
shown, the reel 1 includes four substantially identical motor mount
provisions, two defined by each support endplate 120, which may
provide the flexibility for mounting the motor in the location that
best suits the particular configuration of the reel 1. In other
instances, the substantially similar support and spool endplates
may facilitate assembly of the reel 1 regardless of which
respective endplate is used on either side of the reel 1.
[0029] FIG. 1b illustrates one embodiment of a hand crank system
that may be implemented in conjunction with the reel 1 in order to
drive the rotation of the spool assembly 10. A hand crank support
assembly 165 is coupled to a support endplate 120 and attached
thereto with appropriate fasteners via apertures 129. In some
instances, such as that shown, four substantially identical sets of
apertures 129 may be provided, two sets being defined by each
support endplate 120. Such provisions may provide the flexibility
as to where the hand crank support assembly 165 is located and may
provide easier assembly of the reel 1 regardless of which
respective endplate is used on either side of the reel 1. The hand
crank support assembly 165 rotatably supports a hand crank
driveshaft 167 (e.g., via a bearing component of the hand crank
support assembly 165). A hand crank sprocket 166 is coupled to one
end of the hand crank driveshaft 167, and engages a second spool
sprocket 62 coupled to one of the spool endplates 20. A lever (not
shown) may be removably coupled to the other end of the hand crank
driveshaft 167 to allow a user to rotate the driveshaft 167 and,
thereby, cause the spool assembly 10 to rotate relative to the
support assembly 110.
[0030] FIG. 2a is a perspective view of one embodiment of the
support assembly 110, comprising two substantially similar opposing
support endplates 120. FIG. 2b depicts a single support endplate
120, according to such an embodiment. The support endplate 120 is
comprised of a polymeric material such as, for example, low density
polyethylene (LDPE) or high density polyethylene (HDPE). In one
exemplary embodiment, at least one of the support endplates 120 is
comprised of, for example, a rotomolded polymeric material,
wherein, in some instances, the rotomolded polymeric material may
include a foam core such as, for example, a polyurethane foam
core.
[0031] In the embodiment illustrated by FIG. 2a, the two opposing
planar support endplates 120 are interconnected, for example, by
four elongate support endplate connecting members 130. One skilled
in the art will appreciate, however, that other embodiments of the
support assembly 110 may include any number of such support
endplate connecting members 130. Similarly, the connecting members
130 may be positioned at locations or in orientations between the
support endplates 120 other than those illustrated by the figures.
In one embodiment, two support endplate connecting members 130 may
be located parallel to each other (e.g., as shown in FIGS. 1a-2a)
and configured to allow the hose, cord, or cable to pass
therebetween. In this regard, the two parallel support endplate
connecting members 130 may serve as a guide for guiding the hose,
cable, or cord onto the spool assembly 10. In other embodiments, a
separate hose guide may be coupled to the support assembly 110 for
guiding the hose, cable, or cord onto the spool assembly 10. The
support endplates 120 are substantially identical, or at least
substantially similar, and, as such, may be interchangeable between
sides of the support assembly 110.
[0032] Although not shown in the figures, the support assembly 110
may comprise various other apertures or structures such as
structures for mounting the support assembly to a vehicle, a floor,
the ground, a wall, a ceiling, a set of wheels, etc. Such
structures may be molded into the support assembly 110 or may be
separate structures that can be attached to the support endplates
120 or support endplate connecting members 130.
[0033] FIG. 3a is a perspective view of one embodiment of the spool
assembly 10, comprising two substantially similar opposing spool
endplates 20, coupled together by at least one, or a plurality, of
elongate spool endplate connecting members 30. FIG. 3b depicts a
single spool endplate 20 comprised of, for example, a polymeric
material, such as low density polyethylene (LDPE) or high density
polyethylene (HDPE). In one exemplary embodiment, at least one of
the spool endplates 20 is comprised, for example, of a rotomolded
polymeric material, wherein, in some instances, the rotomolded
polymeric material may include a foam core such as, for example, a
polyurethane foam core. The spool endplates 20 are substantially
identical, or at least substantially similar and as such, may be
interchangeable between sides of the spool assembly 10.
[0034] The spool endplates 20 may also define apertures 23 for
fastening the axles 40 and 41 to the spool endplates 20. In
addition, the spool endplates 20 may further define a circular
aperture 42 disposed about the center of the endplates 20 so that
the axles 40 and 41 may pass therethrough. The apertures 42 may
also be used to pass a pipe, hose, or cable therethrough as an
extension or connection from one end of the hose, cord, or cable
wound on the spool assembly 10, to one end of an external hose,
cord, or cable. In instances where the reel 1 is configured for
storing a hose, one of the axles 41 may comprise a pipe 50 used to
connect one end of the hose wound on the reel 1 to one end of an
external hose or pipe. In one embodiment, the end of the pipe 52
that extends out from the support assembly 110 may comprises a
rotatable coupling for removably attaching an external hose or pipe
to the end of the pipe 52 so that, when the axle 41 rotates with
the spool assembly 10, the external hose or pipe connected to the
end 52 of the pipe is not also required to rotate. If the reel 1 is
configured for storing electrical or other cable, the reel 1 may
comprise a cable extension having the appropriate connectors. In
some embodiments, however, no such extension or connector is
implemented, and the cord or cable is simply wound about the spool
assembly 10.
[0035] The spool endplates 20 further define apertures 22 for
connecting the spool endplate connecting members 30 to the spool
endplates 20. The apertures 22 are spaced about the spool endplate
20, in some instances at equal distances from the center of the
spool endplate 20, so that when the spool endplate connecting
members 30 are engaged with the apertures 22, the spool endplate
connecting members 30 cooperate to define a support structure for
supporting the hose, cord, or cable. Although not shown in the
figures, the spool endplates 20 may further define other apertures
that cooperate to define generally concentric perimeters with
respect to the perimeter defined by the illustrated apertures 22.
These additional apertures could also be used for connecting the
spool endplate connecting members 30 to the spool endplates 20.
Such a configuration may allow the dimensions of the support
surface to be appropriately varied by moving the spool endplate
connecting members 30 from one set of the apertures 22 to another
set of concentric apertures defined by the spool endplates 20. In
one embodiment, the apertures 22 are used both to connect the spool
endplate connecting members 30 and the sprockets 60 and 62 of the
drive mechanism to the spool endplates 20. The details of such a
connection are described in greater detail below in accordance with
one embodiment of the invention. In another embodiment (not shown),
other apertures or structures are defined by the spool endplates 20
for attaching the sprockets 60 and 62 or other items to the spool
endplates 20.
[0036] In some instances, the spool endplates 20 may further
comprise at least one circular step portion 21 that extends
inwardly toward the center of the spool assembly 10. These step
portions 21 may function, for example, to partially support at
least a portion of the wound hose, cord, or cable. In addition, the
outward face of the spool endplate 20 may define at least one
recess 24. This recess 24 may provide, for instance, a space for
receiving the sprocket 62 used in the hand crank drive system. If a
motor-driven drive system is used in the reel 1, spacers 25 may be
used for separating the sprocket 61 from the side of the spool
endplate 20 to allow sufficient room for the chain 65 to pass over
the sprocket 60 and around the motor sprocket 161. Such steps and
recesses may further add structural integrity to the spool
endplates 20. In other embodiments, however, the spool endplates 20
do not have any step or recess.
[0037] FIG. 4a is an illustration of an exemplary embodiment of an
endplate connecting member 230, such as that which can be used as a
spool endplate connecting members 30 and/or a support endplate
connecting members 130. The connecting member 230 is elongate with
opposed ends. In some instances, the connecting member 230 may be
cylindrical. The connecting member 230 may be, for example, a solid
member or a hollow tube, and made of any material suitable for
application to the support and/or spool assemblies 110, 10. In one
embodiment, the connecting members 230 may be comprised of hollow
metal tubing or pipe such as steel tubing, and may be plated,
painted, or otherwise coated or treated to improve the corrosion
resistance thereof. Such connecting members 230 are configured to
extend between the support or spool endplates 120, 20, as
appropriate, so as to couple the respective endplates together. In
some instances, each connecting member 230 comprises two defined
connecting elements disposed about the ends thereof, with the
connecting elements being separated by an elongate medial portion
232. The separation distance W between the defined connecting
elements determines the width W.sub.1 of the support assembly or
the width W.sub.2 of the spool assembly.
[0038] The connecting elements may comprise, for example, threaded
end portions 231 of the connecting member 230, wherein the threaded
end portions 231 may be configured to operably engage a
complementary threaded securing member 240. FIGS. 4b and 4c
illustrate two different views of the securing member 240 according
to one embodiment of the present invention. In such instances, the
securing member 240 may comprise a first head portion 241 and a
continuous second tubular portion 242, wherein the internal wall
243 of the tubular portion 242 may be threaded so as to be capable
of engaging the threaded end 231 of the connecting member 230. The
head portion 241 is of a greater dimension than the tubular portion
242 and may define apertures 244, 245 configured to be engaged by a
complementary tool (not shown) for tightening or loosening the
securing member 240 with respect to an engagement with the
connecting member 230. The aperture 244 may also be threaded and
configured to engage a screw or bolt, for example, for attaching
the sprockets 60 and/or 61 to the spool assembly 10. For example,
the sprockets 60, 61 may define apertures corresponding to the
apertures 22 used for engaging the spool endplate connecting
members 30. Thus, after the spool endplate connecting members 30
are attached to the spool endplates 20 using the securing members
240, the sprockets 60 and/or 61 can be bolted to the spool
endplates 20 using apertures 244 in the securing members 240.
[0039] FIG. 4d illustrates a cross-sectional view of two endplate
connecting members 230 coupled to a support endplate 120 using
securing members 240, according to one embodiment of the present
invention. The apertures 122 defined by the support endplate 120
are configured to receive the tubular portion 242 of the securing
member 240 such that the head portion 241 of the securing member
240 abuts the support endplate 120 when securing member 240 is
screwed onto the threaded end 231 of the connecting member 230. The
diameter of the threaded end 231 of the connecting member 230 is
less than the diameter of the medial portion 232 so that a washer
250 may be disposed about the threaded end 231, without being
movable over the medial portion 232 of the connecting member 230.
In this manner, when the securing member 240 is screwed onto the
end 231 of the endplate connecting member 230, the support endplate
120 is secured between the washer 250 and the head portion 241 of
the securing member 240. In other embodiments, the diameter of the
threaded portion 231 of connecting member 230 may be sufficiently
less than the diameter of the medial portion 232 such that a washer
250 may not be necessary. The spool endplate connecting members 30
may be coupled to the spool endplates 20 in a similar manner to
that disclosed herein with reference to the support assembly
110.
[0040] FIG. 4e is a perspective view of a support assembly 110
utilizing the endplate connecting members 230, securing members
240, and washers 250 to connect the two support endplates 120,
according to one embodiment of the present invention. The spool
assembly 10 can be formed in a similar manner using endplate
connecting members 230, securing members 240, and washers 250. As
can be seen in the figures, the length W of the medial portion 232
of the connecting members 230 generally determines the distance
W.sub.1 or W.sub.2 between the support endplates 120 or spool
endplates 20, respectively.
[0041] One skilled in the art will thus appreciate that embodiments
of the present invention facilitates adjustability of the width of
the support assembly 110 and/or the spool assembly 10, by changing
the connecting members 230, as appropriate. That is, various sets
of connecting members 230 may be formed, with each set having a
different length W of the medial portion 232 between the threaded
end portions 231 of the connecting member 230, whereby the width of
the support and/or spool assemblies 110, 10 can be readily varied
to meet the requirements of a particular application. This
adjustability may be advantageous since the support assembly 110
can be readily adjusted to suit mounting constraints and support
needs, while the spool assembly 10 can be readily adjusted to suit
size constraints and spool capacity needs. Similarly, for instance,
the material used for the connecting members 230 or the gauge of
the connecting members 230 may be varied depending upon the
strength requirements or weight constraints for the reel 1. Thus,
the reel 1 can be readily customized by changing the connecting
members 230.
[0042] FIGS. 5a and 5b illustrate another exemplary embodiment of
an endplate, where one or more tubular inserts 246 are associated
with one or more of the apertures 122 to provide, for example,
greater strength and rigidity of the reel assembly 1 by reinforcing
the endplate 120 about the apertures 122. The tubular inserts 246
may be made from a metallic material, such as aluminum. For
instance, the tubular inserts 246 may be cut from hollow metal
tubing or pipe, such as aluminum tubing. The tubular inserts 246
comprise an outside diameter and an inside diameter. Preferably,
the outside diameter is such that the insert 246 fits snugly within
the aperture 122 defined by the endplate 120, and the inside
diameter is such that the connecting member 230 fits snugly within
the tubular insert 246.
[0043] For example, FIG. 5b illustrates a cross-sectional view of a
portion of a support assembly 110 implementing such tubular inserts
246, according to one embodiment of the present invention. FIG. 5b
shows two securing members 240 being used to couple two connecting
members 230 to a support endplate 120 that is equipped with two
tubular inserts 246. As can be seen in the figure, the tubular
insert 246 is configured to receive the tubular portion 242 of the
securing member 240 which is screwed onto the threaded end portion
231 of the endplate connecting member 230. In one embodiment, the
length of the tubular insert 246 is roughly the width of the
endplate 120 at the location of the aperture 122, such that the
tubular insert 246 is secured between the washer 250 and the head
portion 241 of the securing member 240 when the securing member 240
is screwed onto the end of the connecting member 230, as shown in
FIG. 5b.
[0044] In one embodiment, the tubular inserts 246 are molded into
the polymeric endplates 120 at the time the endplates 120 are
molded. In such an embodiment, the molded-in inserts 246 define the
endplate apertures 122 configured to receive the ends of the
support endplate connecting members 130 for connecting the support
endplate connecting members 130 to the support endplates 120.
Although FIGS. 5a and 5b illustrate tubular inserts 246 used in
connection with the apertures 122 of a support endplate 120, such
tubular inserts 246 may also be used in a similar manner in
connection with one or more of the apertures 22 of a spool endplate
20.
[0045] One skilled in the art will thus appreciate that embodiments
of the present invention provide an improved reel that may provide
a strong, durable, corrosion resistant, lightweight, modular and
customizable reel that is relatively easy to manufacture and
assemble. For example, according to one embodiment of the present
invention, a supply of substantially similar polymeric spool
endplates can be made from a first mold and a supply of
substantially similar polymeric support endplates can be made from
a second mold, with both supplies of endplates being manufactured
with a single rotomolding machine. A supply of substantially
similar endplate connecting members, varying in length (and/or
width), can also be manufactured for use as spool endplate
connecting members 30 and/or support endplate connecting members
130.
[0046] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *