Reel wrap

Abstract

A reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, and a reel width extending from an outer margin of a first of the pair of end plates to an outer margin of a second of the pair of end plates, said reel wrap includes a wrap central portion, said central portion means being substantially continuous and having a width between central portion edge margins at least coextensive with the width of the reel for spanning and enclosing an area between said pair of end plates. And includes first and second side portions for securing the central portion to the reel, the first and second side portions being securable to a respective side plate of the reel proximate a circumferential edge margin of the respective side plate of the reel. A method of wrapping a reel is further included.

Description

RELATED APPLICATION

[0001] The present application claims the benefit of U.S. Provisional Application No. 60/214,998 filed Jun. 29, 2000, which is incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to the protection of materials stored on a reel and, more particularly, to a corrugated wrap that is used to wrap the circumference of a reel thereby providing protection to the materials stored thereon.

BACKGROUND OF THE INVENTION

[0003] Traditionally, wooden spools or reels that are used to transport, store, and dispense various materials, e.g., fiber optics, other types of transmission cables, wires, etc., have had their contents protected through use of wood lagging strips, as shown in the prior art of FIG. 1.

[0004] Referring to FIG. 1, the traditional, prior art manner of preparing a reel 10 for shipping through the use of wood lagging 12 is shown. Reel 10 is generally fabricated from wood and includes a central spool 14 and a pair of end plates 16. Various types of wire and/or cable 18 are wrapped about the central spool 14 and maintained thereon by virtue of end plates 16 allowing reel 10 to operate as a shipment, storage and dispensement container all in one. To prepare reel 10 for shipment, wood lags (lagging strips) 12 are placed one-by-one around the circumference of reel 10, requiring significant preparation time. Each wood lag 12 is secured at each end by a nail 19 to one of end plates 16. The nail is directed into the width 20 of each of end plates 16 rather than the interior face 22 or exterior face 23 of end plates 16. As such, a nail directed at an angle presents the possibility of extending through the interior face 22 of end plate 16, resulting in an unreliable wood lag and the possibility of damaging the contents of reel 10.

[0005] Each of the lagging strips 12 has been cut to the width of the reel and secured to end plates through the use of nails and a nail gun. The wood lagging 12 presents gaps between individual lagging strips through which foreign material and varmints may attack the reel contents. The securing and subsequent removal of the lagging strips 12 from the reel 10 adds significant time, and resultant costs, to the reel shipping process. The use of nails and a powered nail gun provides the possibility of injury to the individual preparing the shipment and, as well, the possibility of injury to the spool contents through virtue of a misdirected, long-shanked nail. Additionally, the wood lagging 12 itself adds significant cost to the shipping due to the weight the lagging adds to the reel and its contents. Further, the disposal and/or re-use of the wood lagging 12 is not easily facilitated and also presents a significant recycling concern. Similar problems are presented by plywood and masonite lagging when used in place of the wood lagging 12.

[0006] In an effort to address at least some of the problems described above, one manufacturer has produced an alternative to wood lagging 12 Specifically, the alternative is a triple-layered material, i.e., an inner layer of polypropylene foam cushioning, a middle layer of recycled polypropylene, and an outer layer of spunbonded polypropylene. The inner layer is placed in direct contact with contents of the reel and is wrapped directly about the contents rather than about the circumference of the reel end plates, as shown in the prior art of FIG. 2. The material is secured against the contents of the reel through use of metal banding strips, leaving the end plates exposed.

[0007] Referring to FIG. 2, the prior art alternative to the configuration of FIG. 1 is shown. In the prior art embodiment of FIG. 2, a triple-layered material 24, i.e., an inner layer of polypropylene foam cushioning, a middle layer of recycled polypropylene, and an outer layer of spunbonded polypropylene, is wrapped about the contents of reel 10 and is positioned within the diameter of end plates 16. Material 24 is held in position, i.e., in direct contact with the contents of reel 10, through use of one or more metal banding strips 26. As a result of this direct contact, possible damage to the contents of reel 10 is increased according to the pressure applied by metal banding strips 26 upon the contents.

[0008] The alternative described above with reference to FIG. 2 does significantly reduce the time needed to wrap and unwrap the reel, it does reduce the overall weight of the reel, and it does eliminate the need for nails and the possible injury they may cause. However, it introduces new problems that were not present with wood lagging. Because the material 24 of the alternative approach is in direct contact with the contents of the reel 10, there is the possibility that the pattern of the material 24 will be imprinted on the contents of the reel 10. Further, because this alternative approach wraps the contents of the reel rather than the circumference of the end plates of the reel, there is a possibility that the exposed end plate 16 of a reel 10 will roll into the contents of another reel 10, thereby damaging its contents.

[0009] As such, there is a need in the art for a product that addresses the problems presented by wood, plywood, and masonite lagging as well as the problems presented by the above-described alternative approach.

SUMMARY OF THE INVENTION

[0010] The needs described above are in large measure met by the corrugated reel wrap of the present invention. The reel wrap is designed to wrap a reel having a central spool that separates two end plates. The reel wrap generally comprises a substantially continuous central portion having two side portions operably coupled to a respective center portion side margin. Each of the side portions of the wheel wrap of the present invention include a number of tabs that are securable to the end plates of the reel. The width of the central portion is at least as wide as the reel, thereby allowing the central portion to span and enclose the area between the end plates of the reel.

[0011] The side portions are preferably unitary with the central portion allowing the complete reel wrap to be fabricated from a plastic or plasticized material, which preferably includes a corrugated layer that is laminated to a single face, or sandwiched between two faces. Since the reel is of a wood material, the tabs of the side portions of the reel wrap are preferably secured to the end plates of the reel with staples; however, other fasteners may be used. The tabs are configured to allow substantially gap-free contact between the central portion and the end plates when the tabs are secured to the end plates providing for the area intermediate the end plates of the reel to be substantially, completely enclosed.

[0012] The method for wrapping the reel wrap generally comprises the steps of placing or laying the wrap about the reel so that the central portion of the wrap covers the central spool, and securing the tabs to the exterior surface of the end plates of the reel with the previously described fasteners.

[0013] One object of the present invention is to utilize plastic or plasticized materials to better facilitate recyclability. In addition, the preferred materials provide flexibility in material colors, and even permit the use of translucent materials, simplifying visual inspections after the reel has been wrapped. This preferred material also provides increased protection and resistance from outside forces and elements.

[0014] Another object of the present invention is to provide a reel wrap weighing significantly less when compared to prior art lagging methods. This reduced wrap weight substantially reduces shipping costs.

[0015] Yet another object of the present invention is to minimize labor costs associated with reel preparation by significantly reducing the time taken to secure and remove the wrap. This object is achieved by implementing a generally unitary reel wrap and simpler fastening methods.

[0016] A further object of the present invention is to reduce the likelihood of injury to the person securing or removing the wrap from the reel. This injury reduction is achieved through the use of generally short fasteners which are directed to the exterior surface of the end plates rather than the edge of the end plates.

[0017] Yet a further object of the present invention is to provide a wrap that is easily modifiable so that it can be constructed in different shapes and sizes in accordance with specific needs generally associated with varying reel sizes.

[0018] The present invention is a reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, and a reel width extending from an outer margin of a first of the pair of end plates to an outer margin of a second of the pair of end plates. The reel wrap includes a wrap central portion, the central portion being substantially continuous and having a width between central portion edge margins at least coextensive with the width of the reel for spanning and enclosing an area between said pair of end plates. And the reel wrap includes first and second side portions for securing the central portion to the reel, the first and second side portions being securable to a respective side plate of the reel proximate a circumferential edge margin of the respective side plate of the reel. The present invention is further method of wrapping a reel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is a prior art configuration of a reel, the contents of which have been protected through the use of wood lagging about the circumference of the reel;

[0020] FIG. 2 is a prior art configuration of a reel, the contents of which have been protected through the use of a wrap that is wrapped about and in direct contact with the contents of the reel;

[0021] FIG. 3 depicts a reel, the contents of which have been protected through the use of a corrugated reel wrap of the present invention;

[0022] FIG. 4 depicts a corrugated material that may be used in the corrugated reel wrap of the present invention;

[0023] FIG. 5 depicts an alternative corrugated material that may be used in the corrugated reel wrap of the present invention;

[0024] FIG. 6 depicts one pattern, having closely spaced tabs, for the corrugated reel wrap of the present invention;

[0025] FIG. 7 depicts an alternative pattern, having set-apart tabs, for the corrugated reel wrap of the present invention;

[0026] FIG. 8 depicts the corrugated reel wrap, with the pattern of FIG. 7, wrapped partially about a reel; and

[0027] FIG. 9 depicts the corrugated reel wrap of the present invention being applied to a reel through use of a pneumatic fastening tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] A corrugated reel wrap of the present invention is shown generally at 50 in the figures and is used to protect and shield the contents of a reel. The corrugated reel wrap 50 provides for fast installation and removal, significantly reduces the amount of weight added to the reel compared to wood lagging, and reduces the possibility of injury to the shipper and/or contents of the reel.

[0029] Corrugated reel wrap 50 of the present invention is shown in FIGS. 3-5. As FIG. 3 depicts, corrugated reel wrap 50 is designed to span the overall width of reel 10 and to be secured to the exterior of reel 10 by staples 51, thereby avoiding the problems associated with nailing wood lagging to the end plates. Staples 51 are selected with a length that is insufficient to penetrate the end plate 16, thereby protecting the contents of the reel 10 from damage. Referring to FIGS. 3 and 6, corrugated reel wrap 50 incorporates a central portion 56, which is of sufficient width to extend between end plates 16 of reel 10, and two side portions 58 that are preferably unitary with central portion 56, being joined at a respective side margin of the central portion 56. Each of side portions 58 includes a plurality of tabs 60 that have been preferably die-cut to include angled sides 62 that extend into an arc portion 64 that is common with the angled side 62 of the next proximate tab 60. Corrugated reel wrap 50 may be of any desired length and width that is suitable to a specific application.

[0030] As FIG. 4 depicts, corrugated reel wrap 50 is not a wood product but rather is a multi-layered material manufactured from high-density polyethylene (HDPE), i.e., a plastic, having a basis weight of 300 to 500 lbs. Of course, other plastics or plasticized materials, e.g., plastic coated fiberboard, may be used without departing from the spirit or scope of the invention. HDPE is used to create a corrugated reel wrap 50 that preferably incorporates two outside liners 52 and a fluted center 54, as shown in FIG. 4. Alternatively, corrugated reel wrap 50 may include only a single outside liner 52 in combination with fluted center 54, as shown in FIG. 5. The flutes 55 of fluted center 54 may extend along the length or along the width of corrugated reel wrap 50. Corrugated reel wrap 50 may be manufactured through lamination, extrusion, or other like processes.

[0031] Because corrugated reel wrap 50 is manufactured from HDPE it is 100% recyclable, thus eliminating the element of waste product that results from wood lagging. Further, because corrugated reel wrap 50 is manufactured from HDPE, it may be customized with minimal investment and can be made available in a wide range of colors, including translucents. The HDPE material also means that corrugated reel wrap 50 is unaffected by water, is stronger and more durable than corrugated fiberboard, is extremely lightweight, will not rust, rot, mildew or corrode like metal or wood, and will resist a wide range of chemicals, grease and dirt. The HDPE material allows corrugated reel wrap 50 to be printed on easily and clearly, and to be tear, puncture, and impact-resistant for protection of the contents of reel 10. The HDPE material also allows for corrugated reel wrap 50 to be made anti-static, non-conductive, ultra-violet inhibiting, flame retardant, corrosion retardant, and/or non-skid if desired. Additionally, corrugated reel wrap 50 may be made with FDA approved resins.

[0032] FIGS. 7 and 8 depict corrugated reel wrap 50 incorporating an alternative pattern to that presented in FIGS. 3 and 6; of course, numerous other patterns may be used for corrugated reel wrap 50 without departing from the spirit or scope of the invention. The alternative pattern finds corrugated reel wrap having a central portion 56, which is of sufficient width to extend between end plates 16 of reel 10, and two side portions 58 that are preferably unitary with central portion 56. Each of side portions 58 includes a plurality of tabs 60 that have been preferably die-cut to include angled sides 62. However, different from the pattern described in the paragraph above, tabs 60 are separated by an elongate space 63 that is substantially equivalent in width to that of one of tabs 60.

[0033] FIG. 9 depicts the application of corrugated reel wrap 50 to a reel 10. As shown, corrugated reel wrap 50 is positioned such that central portion 56 extends between end plates 16 of reel 10, allowing tabs 60 to protrude outward. To secure tabs 60 to reel 10, they are manually bent downward and fastened, preferably through use of a pneumatic fastening tool 66 (e.g. stapler, nail gun, etc.) to exterior face 23 of end plate 16, causing central portion 56 to smoothly lie along the edges of end plates 16. Arc portion 64 and spacing between tabs 60 allow each tab 60 to be bent individually without stress on proximate tabs 60 and to lie flat against end plate 16 without causing gaps between end plates 16 and central portion 56. Only one fastener 68 (including, for example, staple 51) is needed per tab 60 to secure it to reel 10. Fasteners 68 are selected to have a shank length such that each of fasteners 68 does not penetrate end plate 16 and protrude through interior face 22 upon being secured to end plate 16. The process of bending and fastening is repeated for each tab 60 through the rolling of reel 10 until all tabs 60 are secured and the area intermediate end plates 16 of reel 10 is enclosed.

[0034] Completing the enclosure of the area intermediate end plates 16 may be achieved by overlapping the ends of corrugated reel wrap 50. Using this manner of completing the enclosure allows for corrugated reel wrap 50 to be dispensed and cut to a desired length for application to reel 10. Alternatively, corrugated reel wrap 50 may be manufactured to a specific length where the ends overlap to complete the enclosure. Within this alternative, if desired, the ends of corrugated reel wrap 50 may be provided with an interlocking notch 70 and tab 72 combination to complete the enclosure of wrap 50, as shown in FIGS. 3 and 9.

[0035] By using corrugated reel wrap 50 as described above, the time spent by an individual in preparing a reel for shipment is reduced by greater than ⅓ when compared to traditional wood lagging. The time for removing corrugated reel wrap 50 is also significantly reduced over the removal time of wood lagging. Further, corrugated reel wrap 50 is of a greatly reduced weight, compared to wood, plywood, or masonite lagging, for reduced shipping costs. Further, the possibility of injury to the shipper or to the reel contents is reduced by using fasteners of reduced length and preferred placement on end plate 16. For example, staple prongs are of a significantly reduced length and width when compared to that of the shank of a nail which is used with wood lagging. Additionally, the shank of a nail used in fastening the present invention may be shorter than that used in wood lagging since the present invention is secured to exterior face 23 of end plate 16 rather than fully penetrating a piece of wood lagging and then being directed into the width of end plate 16 as is the case in wood lagging.

[0036] Further, by using corrugated reel wrap 50 as described above, only the circumference of a reel 10 is wrapped, i.e., there is no direct contact with the contents of the reel 10 when the contents assume a circumference that is less than the circumference of the end plates 16. There is no possibility that the pattern of the corrugated reel wrap 50 is imprinted on the contents in this condition. When wrapping the circumference of the end plates 16 with corrugated reel wrap 50, a substantially rigid material, the possibility that an object may break through wrap 50 to damage the contents of the reel 10 is virtually eliminated unlike the alternative prior art method shown in FIG. 2. Wrapping of the circumference with corrugated reel wrap 50 also provides a moisture barrier for the underlying contents of reel 10.

[0037] The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.

Claims

1. A reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, said reel wrap comprising:

a central portion, said central portion being spannable across a distance between said pair of end plates; and

first and second side portions operably coupled to respective sides of said central portion, wherein said side portions include a plurality of tabs, each of said plurality of tabs being securable to a one selected of said pair of end plates.

2. The reel wrap of claim 1, wherein said central portion is unitary with said side portions.

3. The reel wrap of claim 2, wherein said central portion and said side portions are fabricated from a material selected from a group consisting of: a plastic material and a plasticized material.

4. The reel wrap of claim 3, wherein said plastic material is a corrugated plastic material and said plasticized material is a corrugated plasticized material.

5. The reel wrap of claim 4, wherein said corrugated plastic material and said corrugated plasticized material is selected from a group consisting of: a single-faced material and a double-faced material.

6. The reel wrap of claim 1, wherein said tabs are securable to said at least one of said pair of end plates with a fastener selected from a group consisting of: a staple and a nail.

7. The reel wrap of claim 1, wherein said tabs are configured to allow substantially gap-free contact between said central portion and said pair of end plates of said reel upon said tabs being secured to said at least one of said pair of end plates.

8. A method of wrapping a reel, wherein said reel includes a central spool separating a pair of end plates, said method comprising:

forming a wrap having a central portion and two opposed side portions disposed proximate side margins of said central portion, and forming said side portion including a plurality of tabs, and forming said central portion to span a distance between said pair of end plates;

placing the wrap about a circumference of said pair of end plates;

securing said plurality of tabs of a first side portion to a first of said pair of end plates; and

securing said plurality of tabs of a second side portion to a second of said pair of end plates.

9. The method of claim 8, including forming said central portion unitary with said side portions.

10. The method of claim 9, including fabricating said central portion and said side portion from a material selected from a group consisting of: a plastic material and a plasticized material.

11. The method of claim 10, including forming said plastic material of a corrugated plastic material and forming said plasticized material of a corrugated plasticized material.

12. The method of claim 11, including selecting said corrugated plastic material and said corrugated plasticized material from a group consisting of: a single-faced material and a double-faced material.

13. The method of claim 8, wherein said step of securing said plurality of tabs is selected from a group consisting of: stapling said plurality of tabs to the respective end plate and nailing said plurality of tabs to the respective pair of end plate.

14. The method of claim 8, wherein said step of placing a wrap about said circumference of said pair of end plates includes overlapping ends of said wrap.

15. The method of claim 8, including configuring said tabs to allow substantially gap-free contact between said central portion and said pair of end plates of said reel upon completing said step of securing said plurality of tabs.

16. A reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, said reel wrap comprising:

central portion means, said central portion means being substantially continuous for spanning and enclosing an area between said pair of end plates; and

first and second side portion means for securing the central portion means to the reel, the first and second side portion means being securable proximate a circumferential edge margin of a respective side plate of the reel.

17. The reel wrap of claim 16 wherein said side portion means include a plurality of tab means, each of said plurality of tab means for being secured to a one of said pair of end plates.

18. The reel wrap of claim 16, said central portion means being unitary with said side portion means.

19. The reel wrap of claim 16, wherein said central portion means and said side portion means are fabricated from a material selected from a group consisting of: a plastic material and a plasticized material.

20. The reel wrap of claim 19, wherein said plastic material is a corrugated plastic material and said plasticized material is a corrugated plasticized material.

21. The reel wrap of claim 20, wherein said corrugated plastic material and said corrugated plasticized material is selected from a group consisting of: a single-faced material and a double-faced material.

22. The reel wrap of claim 17, wherein said tab means are securable to said at least one of said pair of end plates with a fastener selected from a group consisting of: a staple and a nail.

23. The reel wrap of claim 17, wherein said tab means are configured to allow substantially gap-free contact between said central portion means and said pair of end plates of said reel.

24. A reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, and a reel width extending from an outer margin of a first of the pair of end plates to an outer margin of a second of the pair of end plates, said reel wrap comprising:

a wrap central portion, said central portion being substantially continuous and having a width dimensions extending between central portion edge margins being at least coextensive with the width of the reel for spanning and enclosing an area between said pair of end plates; and

first and second side portions for securing the central portion to the reel, the first and second side portions being securable to a respective side plate of the reel proximate a circumferential edge margin of the respective side plate of the reel.

25. The reel wrap of claim 24 wherein said side portion means include a plurality of tabs, each of said plurality of tabs for being secured to a one of said pair of end plates.

26. The reel wrap of claim 24, said central portion being unitary with said side portions.

27. The reel wrap of claim 24, wherein said central portion and said side portions are fabricated from a material selected from a group consisting of: a plastic material and a plasticized material.

28. The reel wrap of claim 27, wherein said plastic material is a corrugated plastic material and said plasticized material is a corrugated plasticized material.

29. The reel wrap of claim 28, wherein said corrugated plastic material and said corrugated plasticized material is selected from a group consisting of: a single-faced material and a double-faced material.

30. The reel wrap of claim 25, wherein said tabs are securable to said at least one of said pair of end plates with a fastener selected from a group consisting of: a staple and a nail.

31. The reel wrap of claim 30, wherein said tabs are configured to allow substantially gap-free contact between said central portion and said pair of end plates of said reel.

32. A reel wrap for wrapping a reel, the reel having a central spool separating a pair of end plates, said reel wrap comprising:

a reel wrap body being securable to the reel, the reel wrap body acting in cooperation with the reel when secured to present a substantially continuous cylindrical shape having space defined therein for substantially enclosing a product wound on the central spool.

33. The reel wrap of claim 32 including a first and a second side portion, each of said side portions including a plurality of tabs, each of said plurality of tabs for being securable to a one of said pair of end plates.

34. The reel wrap of claim 33, including a central portion, said central portion being unitary with said side portions.

35. The reel wrap of claim 34, wherein said central portion and said side portions are fabricated from a material selected from a group consisting of: a plastic material and a plasticized material.

36. The reel wrap of claim 35, wherein said plastic material is a corrugated plastic material and said plasticized material is a corrugated plasticized material.

37. The reel wrap of claim 36, wherein said corrugated plastic material and said corrugated plasticized material is selected from a group consisting of: a single-faced material and a double-faced material.

38. The reel wrap of claim 33, wherein said tabs are securable to said at least one of said pair of end plates with a fastener selected from a group consisting of: a staple and a nail.

39. The reel wrap of claim 38, wherein said tabs are configured to allow substantially gap-free contact between said central portion and said pair of end plates of said reel.