Abstract: A die and method of assembling a high torque capacity metal spool. The spool comprises a cylindrical barrel, a pair of flanges and a pair of flange hubs. The die includes a support member and a curling member that is adapted to move relative to the support housing. The die is adapted to be driven towards a matching die to press a spool therebetween. Each curling member includes an annular curling face which is adapted to curl and compress metal edges of the cylindrical barrel, the flanges and the flange hubs into tightened curls. The tightened curls secure the cylindrical barrel with the flanges and flange hubs. Each die further includes a plurality of nibs carried by the support housings which project outward from the curling face of the curling member after the tightened curls have been formed to swage a plurality of detents into the tightened curls of the spool. The resulting detents in the metal spool provide for increased torque transfer between the flanges, the flange hubs and the cylindrical barrel.

Abstract: A wooden spool held together with a novel tie rod assembly and a method of assembly the spool between a pair of dies. The novel tie rod assembly includes elongate tie rods having a bent end or otherwise deformed first end and a plurality of grooveless retaining rings. The tie rods are inserted through the end flanges and the transverse barrel of the of the spool. The retaining rings are pressed axially on the smooth second ends of the tie rods which project axially from one of the flanges. The spool can be assembled between a pair of dies. The base die includes locating recesses to receive the bent ends of the tie rods and the top die includes engaging pins for pressing the retaining rings on the opposite ends of the spool.

Abstract: A wire spool comprising three structural components including two end flanges and a rigid fiberboard barrel. The end flanges may be molded plastic or stamped sheet metal. The end flanges have central plug portions that are mechanically locked into the barrel. The central plug portions include teeth which dig into the barrel to substantially permanently secure the end flanges to the barrel such that the wire spool has sufficient strength to allow electricians to pick up a fully loaded wire spool by the end flange and such that the end flanges cannot typically be removed by hand except with the assistance of leverage tools. The plug portion also may include elongate axially extending lugs that engage the barrel and enhance torque transfer between the barrel and the end flanges.

Abstract: A die and method of assembling a high torque capacity metal spool. The spool comprises a cylindrical barrel, a pair of flanges and a pair of flange hubs. The die includes a support member and a curling member that is adapted to move relative to the support housing. The die is adapted to be driven towards a matching die to press a spool therebetween. Each curling member includes an annular curling face which is adapted to curl and compress metal edges of the cylindrical barrel, the flanges and the flange hubs into tightened curls. The tightened curls secure the cylindrical barrel with the flanges and flange hubs. Each die further includes a plurality of nibs carried by the support housings which project outward from the curling face of the curling member after the tightened curls have been formed to swage a plurality of detents into the tightened curls of the spool. The resulting detents in the metal spool provide for increased torque transfer between the flanges, the flange hubs and the cylindrical barrel.

Abstract: A die and method of assembling a high torque capacity metal spool. The spool comprises a cylindrical barrel, a pair of flanges and a pair of flange hubs. The die includes a support member and a curling member that is adapted to move relative to the support housing. The die is adapted to be driven towards a matching die to press a spool therebetween. Each curling member includes an annular curling face which is adapted to curl and compress metal edges of the cylindrical barrel, the flanges and the flange hubs into tightened curls. The tightened curls secure the cylindrical barrel with the flanges and flange hubs. Each die further includes a plurality of nibs carried by the support housings which project outward from the curling face of the curling member after the tightened curls have been formed to swage a plurality of detents into the tightened curls of the spool. The resulting detents in the metal spool provide for increased torque transfer between the flanges, the flange hubs and the cylindrical barrel.

Abstract: A high torque capacity metal spool. The spool comprises a cylindrical barrel, a pair of flanges and a pair of flange hubs. Formed metal curls formed of metal edges of the cylindrical barrel, the flanges and the flange hubs secure the cylindrical barrel to the flanges and flange hubs. The spool includes a plurality of detents in the tightened curls of the spool. The detents in the metal spool provide for increased torque transfer between the flanges, the flange hubs and the cylindrical barrel. The ability to transfer torque increases the applicability of the spool to wire winding and pulling functions. Flattening paste also covers a metal surface in the curl to increase the coefficient of friction therein and further increase the torque transmissibility capacity.