Spirally wound channel core

Abstract

A spool has a spirally-wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web. The channel is oriented with the pair of arms parallel to the axis of the spool and with the central web extending radially, relative to the axis of the spool. The channel has a plurality of adjacent windings, a first and second of the arms of spirally-wound channel cumulatively forming the inner and outer surfaces of the spool. The arms are spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is received between the arms of adjacent windings and is retained therein to establish an overlap of windings in the axial direction. Other embodiments feature S, B and E-shaped channels to form the spool, some embodiments having inner and outer layers of channel. The spool is suitable for holding wound, thin metal stock, such as aluminum for making beverage cans, having a smooth outer surface which preserves the smoothness of the wound stock.

1 . A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
 a spirally wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool, the channel having a plurality of adjacent windings, a first of the arms of spirally wound channel cumulatively forming the outer surface and a second of the arms of spirally wound channel cumulatively forming the inner surface, the first arm and the second arm spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is receivable between the arms of adjacent windings and is retainable therein to establish an overlap of windings of the channel in the axial direction.   
     
     
         2 . The spool of  claim 1 , wherein each of the first arm and the second arm has a first portion extending from the central web and a second portion extending from a free end of the arm to a transition portion extending between the first portion and the second portion, the second portion of the first arm and the second portion of the second arm having a first spacing there between approximating a second spacing between an exterior surface of the first portion of the first arm and an exterior surface of the first portion of the second arm. 
     
     
         3 . The spool of  claim 2 , wherein the channel exhibits a third spacing between an exterior surface of the second portion of the first arm and an exterior surface of the second portion of the second arm and the difference between the second spacing and the third spacing approximates a radial thickness of the second portion. 
     
     
         4 . The spool of  claim 3 , wherein the outer surface is cylindrical and smooth. 
     
     
         5 . The spool of  claim 1 , wherein at least one of the first arm and the second arm has an undulating form in cross-section, an interior surface of the undulating form engaging and mating with an exterior surface of an undulating form of an adjacent winding of the channel of the spool. 
     
     
         6 . The spool of  claim 5 , wherein both of the first arm and the second arm have an undulating form in cross-section. 
     
     
         7 . The spool of  claim 6 , wherein the undulating form has first and second bulges separated by a valley, the first bulge extending from the central web. 
     
     
         8 . The spool of  claim 1 , wherein the channel has at least one slot extending into the central web, the slot capable of receiving an end of at least one of the first arm and the second arm of an adjacent winding of the channel. 
     
     
         9 . The spool of  claim 8 , wherein the slot is blind and is angled at an acute interior angle relative to the central web. 
     
     
         10 . The spool of  claim 9 , wherein the channel has a pair of slots, a first slot disposed proximate a junction of the first arm with the central web and a second slot disposed proximate a junction of the second arm with the central web. 
     
     
         11 . The spool of  claim 10 , wherein the first arm and the second arm each have an angled portion proximate a free end thereof which inserts into a corresponding one of the first slot and the second slot of an adjacent winding of the channel. 
     
     
         12 . The spool of  claim 1 , wherein the channel has at least one groove in at least one of the first arm and the second arm disposed proximate the central web, and wherein at least one of the first arm and the second arm has an angled portion proximate a free end thereof which inserts into the groove of an adjacent winding of the channel. 
     
     
         13 . The spool of  claim 12 , wherein the at least one groove is disposed between the central web and the first arm. 
     
     
         14 . The spool of  claim 13 , wherein the at least one groove has a generally V-shaped cross-section. 
     
     
         15 . The spool of  claim 1 , wherein at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition. 
     
     
         16 . A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
 a spirally wound, elongated channel having an S-shaped cross-section with a pair of arms extending from a central web and having a component of extension in opposite directions, a first arm of the pair of arms having a first extension extending from an end of the first arm distal to the central web at an angle relative to the first arm and forming a top portion of the S-shape, a second arm of the pair of arms having a second extension extending from an end of the second arm distal to the central web at an angle relative to the second arm and forming a bottom portion of the S-shape, the second extension pointing towards a portion of the central web, a distal end of the second extension being distal to the second arm and spaced from the central web by a first spacing, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool, the channel having a plurality of adjacent windings, the first arm of adjacent windings of spirally wound channel cumulatively forming the outer surface and the second arm of adjacent windings of spirally wound channel cumulatively forming the inner surface, the first extension receivable between the distal end of the second extension and the central web of an adjacent winding to interlock therewith and establish an overlap in the axial direction.   
     
     
         17 . The spool of  claim 16 , wherein the distal end of the second extension pushes the first extension of an adjacent winding of the channel toward the central web. 
     
     
         18 . The spool of  claim 17 , further comprising a pushing arm extending from the distal end of the second extension, the pushing arm being captured in the interior angle formed between the first extension and the first arm. 
     
     
         19 . A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
 a spirally wound, elongated inner channel having a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web having a component of extension parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool, the inner channel having a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface;   a spirally wound, elongated outer channel having a second central web and a second pair of arms spaced a second distance from one another, the outer channel being oriented with the second central web generally parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool, the outer channel having a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface,   the outer channel wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.   
     
     
         20 . The spool of  claim 19 , wherein the first pair of arms converge towards one another at a distal end thereof and the second pair of arms converge towards one another at a distal end thereof, the first pair of arms with the first central web forming a triangular shape and the second pair of arms with the second central web forming a triangular shape. 
     
     
         21 . The spool of  claim 20 , wherein a first arm of a first adjacent winding of the outer channel and a second arm of a second adjacent winding of the outer channel are disposed within a first triangular shape of a first adjacent winding of the inner channel. 
     
     
         22 . The spool of  claim 20 , wherein a plurality of adjacent windings of the inner channel each capture the first arm and the second arm of adjacent windings of the outer channel within the triangular shape, thereby interlocking the inner channel and the outer channel. 
     
     
         23 . The spool of  claim 22 , wherein a plurality of adjacent windings of the outer channel each capture the first arm and the second arm of adjacent windings of the inner channel within the triangular shape, thereby interlocking the inner channel and the outer channel. 
     
     
         24 . The spool of  claim 19 , wherein the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable. 
     
     
         25 . The spool of  claim 19 , wherein the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable. 
     
     
         26 . The spool of  claim 19 , wherein the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable and wherein the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable. 
     
     
         27 . The spool of  claim 26 , wherein the outwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the outer channel and the inwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the inner channel. 
     
     
         28 . The spool of  claim 19 , wherein at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition. 
     
     
         29 . A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
 a spirally wound, elongated inner channel having a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool, the inner channel having a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface;   a spirally wound, elongated outer channel having a second central web and a second pair of arms spaced a second distance from one another, the outer channel being oriented with the second central web parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool, the outer channel having a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface,   
       at least one of the first arm and the second arm of at least one of the inner channel and the outer channel being scrolled inwardly toward the central web. 
     
     
         30 . The spool of  claim 29 , wherein both the first arm and the second arm of at least one of the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape. 
     
     
         31 . The spool of  claim 30 , wherein both the first arm and the second arm of both the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape, at least one of the inner channel and the outer channel having a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween. 
     
     
         32 . The spool of  claim 31 , wherein both the inner channel and the outer channel have a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween, and wherein the outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel. 
     
     
         33 . The spool of  claim 1 , wherein the overlapped windings of C-channel define an internal spiral hollow extending through the spool.