Tape reel and method for manufacturing the same
A tape reel according to the present invention includes: a disk-shape first flange having an opening in its central portion; a disk-shape second age having an opening in its central portion; and a cylindrical hub that includes, on an outer periphery thereof, a first pedestal for receiving the first flange and a second pedestal for receiving the second flange. The first flange and the second flange are joined to the first and second pedestals of the hub, respectively, and extend in a radial direction from the outer periphery of the hub. When viewed along a direction of a rotation axis of the reel, an outer periphery of the first pedestal and an outer periphery of the second pedestal are on circumferences of different concentric circles, and an upper surface of the first pedestal and an upper surface of the second pedestal face the same direction.
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1. Field of the Invention
The present invention relates to a tape reel that achieves high accuracy and a method for manufacturing the same.
2. Description of Related Art
In recent years, means for high-speed information transmission such as optical fibers have made remarkable progress. As a result, it became possible to transmit images and data with an enormous amount of information, while at the same time, there arises an increasing demand for advanced techniques to record, reproduce, and store such images and data. Examples of recording and reproducing media include flexible disks, magnetic drums, hard disks, and magnetic tapes. Tape-shaped recording media such as magnetic tapes play a major role mainly as data backup media, because their recording capacity per reel is large. Examples of the tape-shaped recording media include magnetic tapes and optical tapes.
Usually, the tape-shaped recording medium is used in the state where it is wound around a reel and housed in a cartridge. Lately, with an increase in recording capacity of a tape cartridge, further improvement in shape accuracy and rotational accuracy of a reel of the tape cartridge has been demanded.
The reel falls into two types, namely, a two-piece type and a three-piece type (see JP 10(1998)-320958 A and JP 2002-298542 A, for instance). As shown in
On the other hand, a three-piece type reel corresponds to, for example, the above-described two-piece type reel 100 in which the hub 102 and the second flange 104 are provided as separate components. In the three-piece type reel, the first age, the hub, and the second flange are joined to each other by ultrasonic welding, snap-fitting, or the like.
In both the two-piece type reel and the three-piece type reel, the components thereof generally are manufactured by injection molding of a resin. In the two-piece type reel, the first flange and the hub provided with the second flange are manufactured separately by injection molding. At this time, since the first flange has a flat disk shape, the resin flows smoothly during the injection molding, so that it is possible to manufacture the first flange with high shape accuracy. In contrast, in the hub provided with the second flange, the flange bends with respect to the tape-winding surface of the hub and the thickness of the tape-winding surface of the hub is different from that of the flange. Thus, when the resin flows during the injection molding, an internal pressure in the mold is liable to be nonuniform, which makes it difficult to form the hub and the second flange integrally with high shape accuracy. Accordingly, the shape accuracy of the reel obtained by joining these components also is deteriorated.
On the other hand, in the three-piece type reel, the first flange, the hub, and the second flange are manufactured separately by injection molding. The components of the three-piece type reel can be manufactured with higher shape accuracy as compared with the components of the two-piece type reel, because the components of the three-piece type reel do not have a large bent portion and have a substantially uniform thickness. However, in order to manufacture the three-piece type reel, the flanges need to be joined to both sides of the hub, respectively. Thus, it is usually necessary to perform, after one of the flanges has been joined to the hub, the step of turning over the hub to join the other flange, for example, thereby making the manufacturing process complicated. Also, a method of joining the flanges to both the sides of the hub, respectively, by snap-fitting has been proposed. However, when the flanges are joined by snap-fitting, each fitting portion needs to have a clearance due to its construction, which poses a problem in that the components cannot be fixed together sufficiently after being joined, resulting in deteriorated shape accuracy of the reel as a whole.
When the shape accuracy of the reel is not sufficient as described above, the rotational accuracy of the reel also is deteriorated to make the tape run unstable. This deteriorates the reading accuracy and recording accuracy of recording signals by the drive head, thereby causing errors in reading and recording the recording signals.
SUMMARY OF THE INVENTIONThe present invention is intended to solve the above-described problems and to provide a tape reel that is of a three-piece type with each component having high shape accuracy and is improved in shape accuracy of the reel as a whole and a method for manufacturing such a tape reel efficiently.
A tape reel according to the present invention includes: a disk-shape first flange having an opening in its central portion; a disk-shape second flange having an opening in its central portion; and a cylindrical hub that comprises, on an outer periphery thereof, a first pedestal for receiving the first flange and a second pedestal for receiving the second flange. The first flange and the second flange are joined to the first and second pedestals of the hub, respectively, and extend in a radial direction from the outer periphery of the hub. When viewed along a direction of a rotation axis of the reel, an outer periphery of the first pedestal and an outer periphery of the second pedestal are on circumferences of different concentric circles, and an upper surface of the first pedestal and an upper surface of the second pedestal face the same direction.
A method for manufacturing a tape reel according to the present invention is a method for manufacturing a tape reel that includes: a disk-shape first flange having an opening in its central portion; a disk-shape second flange having an opening in its central portion; and a cylindrical hub that comprises, on an outer periphery thereof, a first pedestal for receiving the first flange and a second pedestal for receiving the second flange, wherein the first flange and the second flange are joined to the first and second pedestals of the hub, respectively, and extend in a radial direction from the outer periphery of the hub, when viewed along a direction of a rotation axis of the reel, an outer periphery of the first pedestal and an outer periphery of the second pedestal are on circumferences of different concentric circles, and an upper surface of the first pedestal and an upper surface of the second pedestal face the same direction. The method includes the steps of: joining the first flange to the first pedestal; and joining the second flange to the second pedestal.
Since the tape reel according to the present invention can achieve high shape accuracy, the rotational accuracy of the reel also is improved, which allows the running stability of the tape to be improved.
Moreover, by the method for manufacturing a tape reel according to the present invention, the above-described tape reel of the present invention can be manufactured efficiently with simple facilities.
BRIEF DESCRIPTION OF THE DRAWINGS
The tape reel according to the present invention is a three-piece type tape reel including: a disk-shape first flange having an opening in its central portion: a cylindrical hub; and a disk-shape second flange having an opening in its central portion. The first flange and the second flange are joined to both sides of the hub, respectively, and extend in a radial direction from an outer periphery of the hub. By configuring the tape reel so as to be a three-piece type tape reel, the shape accuracies of the respective components can be improved.
Furthermore, the hub include, on its outer periphery, a first pedestal for receiving the first flange and a second pedestal for receiving the second flange. When viewed along a direction of a rotation axis of the reel, an outer periphery of the first pedestal and an outer periphery of the second pedestal are on circumferences of different concentric circles, and an upper surface of the first pedestal and an upper surface of the second pedestal face the same direction. With this configuration, it becomes possible to join the first flange and the second flange to the hub from the same direction (the uniaxial direction), which allows an apparatus used for joining the hub and the flanges to be simplified.
Still further, the first flange is joined to the first pedestal, and the second flange is joined to the second pedestal. With this configuration, the flanges can be joined to the hub by ultrasonic welding, caulking, adhesion with the use of an adhering member, or the like, which allows a plurality of components to be fixed and joined with high accuracy. Accordingly the shape accuracy of the reel as a whole after the respective components have been joined also can be improved. It should be noted that means for joining the hub and the flanges is not limited to those described above, and any other means can be used as long as a plurality of components can be fixed and joined with high shape accuracy.
The tape reel according to the present invention is applicable not only to a single-reel type tape cartridge but also to a double-reel type tape cartridge. Moreover, the tape reel according to the present invention can be used not only as a reel of a tape cartridge but also as a reel of a drive.
On the other hand, the method for manufacturing a tape reel according to the present invention is a method for manufacturing the above-described tape reel of the present invention. The method includes the steps of joining the first flange to the first pedestal; and joining the second flange to the second pedestal. According to this method, it becomes possible to join the first flange and the second flange to the hub from the same direction (the uniaxial direction) as described above, thereby allowing a reel having high shape accuracy to be manufactured efficiently. There is no particular limitation on the method of joining the hub and the flanges. However, methods of joining them by ultrasonic welding, caulking, adhesion with the use of an adhering member, or the like can fix and join a plurality of components with high accuracy and also can improve the shape accuracy of the reel as a whole after the respective components have been joined.
Hereinafter, the present invention will be described by way of illustrative embodiments with reference to the drawings.
Embodiment 1
Next, a method for manufacturing the tape reel according to the present embodiment will be described.
First, as shown in
Next, as shown in
According to the manufacturing method of the present embodiment, the first flange 10 and the second flange 20 can be placed on the hub 30 from the same direction, so that it is possible to join the first flange 10 and the second flange 20 without turning over the hub 30. Thus, an apparatus used for joining can be simplified and the joining process can be carried out efficiently.
Furthermore, in the first and second steps described above, by sandwiching the portion to be joined between the first and second welding horns 51, 52 and the receiving jig 50, the loss in welding energy can be suppressed and the welding accuracy can be improved. Note here that a common horn may be used as the first welding horn 51 and the second welding horn 52 in the first and second steps.
Embodiment 2
The tape reel 60 of the present embodiment has substantially the same configuration as the tape reel 40 of Embodiment 1 except that the first flange 15 and the hub 36 are joined by caulking and produces the same effect as the tape reel 40 of Embodiment 1. Moreover, according to a method for manufacturing the tape reel 60 of the present embodiment, the first flange 15 and the second flange 20 can be placed on the hub 36 from the same direction, so that it is possible to join the first flange 15 and the second flange 20 without turning over the hub 36; Thus, an apparatus used for joining can be simplified and the joining process can be carried out efficiently.
Embodiment 3
The tape reel 70 of the present embodiment has substantially the same configuration as the tape reel 40 of Embodiment 1 except that the first flange 80 and the second flange 25 are joined to the hub 30 with the adhesive 82 and produces the same effect as the tape reel 40 of Embodiment 1. Moreover, according to a method for manufacturing the tape reel 70 of the present embodiment, the first flange 80 and the second flange 25 can be placed on the hub 30 from the same direction, so that it is possible to join the first flange 80 and the second flange 25 without turning over the hub 30. Thus, an apparatus used for joining can be simplified and the joining process can be carried out efficiently.
As specifically described above, since the tape reel according to the present invention can achieve high shape accuracy, the rotational accuracy of the reel also is improved, which allows the running stability of the tape to be improved. Consequently, the tape reel according to the present invention can contribute to higher performance of tape cartridges.
Moreover, by the method for manufacturing a tape reel according to the present invention, the above-described tape reel of the present invention can be manufactured efficiently with simple facilities. Thus, the method according to the present invention is extremely valuable from an industrial viewpoint.
The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
Claims
1. A tape reel comprising:
- a disk-shape first flange having an opening in its central portion;
- a disk-shape second flange having an opening in its central portion; and
- a cylindrical hub that comprises, on an outer periphery thereof, a first pedestal for receiving the first flange and a second pedestal for receiving the second flange,
- wherein the first flange and the second flange are joined to the first and second pedestals of the hub, respectively, and extend in a radial direction from the outer periphery of the hub,
- when viewed along a direction of a rotation axis of the reel, an outer periphery of the first pedestal and an outer periphery of the second pedestal are on circumferences of different concentric circles, and an upper surface of the first pedestal and an upper surface of the second pedestal face the same direction.
2. The tape reel according to claim 1, wherein
- an outer diameter of the first pedestal is smaller than an outer diameter of the second pedestal,
- each of the first flange and the second flange has a joining rib on its inner periphery,
- each of the first pedestal and the second pedestal has a joining groove,
- the joining rib of the first flange is joined to the joining groove of the first pedestal by ultrasonic welding, and
- the joining rib of the second flange is joined to the joining groove of the second pedestal by ultrasonic welding.
3. The tape reel according to claim 2, wherein a welding projection is provided on a tip end of the joining rib of each of the first flange and the second flange.
4. The tape reel according to claim 1, wherein
- an outer diameter of the first pedestal is smaller than an outer diameter of the second pedestal,
- the first flange is joined to the first pedestal by caulking, and
- the second flange is joined to the second pedestal by ultrasonic welding.
5. The tape reel according to claim 1, wherein
- an outer diameter of the first pedestal is smaller than an outer diameter of the second pedestal,
- the first flange is joined to the first pedestal with an adhering member, and
- the second flange is joined to the second pedestal with an adhering member.
6. A method for manufacturing a tape reel, the tape reel comprising:
- a disk-shape first flange having an opening in its central portion;
- a disk-shape second flange having an opening in its central portion; and
- a cylindrical hub that comprises, on an outer periphery thereof, a first pedestal for receiving the first flange and a second pedestal for receiving the second flange,
- wherein the first flange and the second flange are joined to the first and second pedestals of the hub, respectively, and extend in a radial direction from the outer periphery of the hub,
- when viewed along a direction of a rotation axis of the reel, an outer periphery of the first pedestal and an outer periphery of the second pedestal are on circumferences of different concentric circles, and an upper surface of the first pedestal and an upper surface of the second pedestal face the same direction,
- the method comprising the steps of:
- joining the first flange to the first pedestal; and
- joining the second flange to the second pedestal.
7. The method according to claim 6, wherein
- an outer diameter of the first pedestal is smaller than an outer diameter of the second pedestal,
- each of the first flange and the second flange has a joining rib on its inner periphery,
- each of the first pedestal and the second pedestal has a joining groove,
- the joining rib of the first flange is joined to the joining groove of the first pedestal by ultrasonic welding, and
- the joining rib of the second flange is joined to the joining groove of the second pedestal by ultrasonic welding.
8. The method according to claim 6, wherein
- an outer diameter of the first pedestal is smaller than an outer diameter of the second pedestal,
- the first flange is joined to the first pedestal by caulking, and
- the second flange is joined to the second pedestal by ultrasonic welding.
9. The method according to claim 6, wherein
- an outer diameter of the first pedestal is smaller than an outer diameter of the second pedestal,
- the first flange is joined to the first pedestal with an adhering member, and
- the second flange is joined to the second pedestal with an adhering member.
Type: Application
Filed: Jan 23, 2007
Publication Date: Aug 2, 2007
Applicant: HITACHI MAXELL, LTD. (Ibaraki-shi)
Inventor: Teruo Sogabe (Osaka)
Application Number: 11/656,424
International Classification: B65H 75/14 (20060101);