Composite industrial winding core and methods

Abstract

A high performance and lightweight composite industrial winding core for winding a thin material stock thereon. In preferred embodiments, the winding core is engineered from fiber reinforced plastic and comprises a pair of elongate winding core bodies aligned along an axis having a generally cylindrical outer face with an inner face that defines the inside of the hollow cylinder. A first end wall and a second end wall enclose the ends of the winding core. A series of spaced axle supports support the winding core bodies. An inner axle face engages with an axle shaft. Portions of the winding core can be joined by an adhesive resin or bonding agent. The axle shaft can include inflatable bladders and can engage an inner tube of the winding core. A method for using a winding core to wind material stock is disclosed.

1 . A winding core comprising:
 a winding core body having a central axis;   said winding core body comprising an outer radial wall;   said outer radial wall having outward facing outer face defining a cylinder;   said outer radial wall having an inward facing inner face defining an internal cylinder;   an end wall enclosing a first end of said winding core body;   an inner radial wall extending from said end wall into said internal cylinder;   said inner radial wall having an inner axle face defining an axle cavity operable for seating an axle therein; and,   said inner radial wall having an outer axle face spaced inward from said inner face.   
     
     
         2 . The winding core of  claim 1  wherein said outer radial wall is thickens as it approaches said end wall. 
     
     
         3 . The winding core of  claim 1  wherein said outer radial wall thickness is substantially constant. 
     
     
         4 . The winding core of  claim 1  further comprising:
 a plurality of axle ribs extending between said outer axle face and said inner face thereby securing said inner radial wall concentric to said outer radial wall. 
 
     
     
         5 . The winding core of  claim 4  wherein said plurality of axle ribs are equally spaced to each other. 
     
     
         6 . The winding core of  claim 4  wherein said plurality of axle ribs are also integral with an inner end face. 
     
     
         7 . The winding core of  claim 1  further comprising:
 a central face; 
 said central face extending between said outer face and said inner face; and, 
 wherein said central face is substantially perpendicular to said central axis. 
 
     
     
         8 . The winding core of  claim 7  further comprising:
 a second winding core body; 
 wherein said first winding core body and said second winding core body are aligned along said central axis; and, 
 wherein said central faces of each winding core body abut each other. 
 
     
     
         9 . The winding core of  claim 8  further comprising:
 an inner axle support; 
 said inner axle support comprising a substantially cylindrical outward radial wall; 
 said outward radial wall sized to fit within said inner space of said winding core body; 
 an inner radial wall with inner axial face thereon forming a cylinder operable to house an axle; 
 a spanning wall spanning between said outward radial wall and said inner radial wall of said inner axle support thereby concentrically securing the position of said outward radial wall in relation to said inner radial wall along said central axis. 
 
     
     
         10 . The winding core of  claim 9  wherein said inner axle support is positioned within said inner spaces overlapping said winding core bodies and bonded in position. 
     
     
         11 . The winding core of  claim 10  further comprising:
 at least one inner tube; 
 said inner tube comprising a cylindrical inner tube wall; 
 said inner tube wall comprising an outward face facing outward; 
 said inner tube wall comprising an interior face facing inward; 
 said interior face defining an axial cavity for housing said axle; and, 
 wherein said at least one inner tube extends between said end axle support and said inner axle support and is aligned with said central axis. 
 
     
     
         12 . The winding core of  claim 11  further comprising:
 an interlock flange at an interior end of said inner radial wall; and, 
 wherein said interlock flange is configured to interlock with said inner tube. 
 
     
     
         13 . The winding core of  claim 1  further comprising:
 an axle; 
 wherein said axle is seated within said axle cavities. 
 
     
     
         14 . The winding core of  claim 9  further comprising an expandable axle. 
     
     
         15 . The winding core of  claim 14  wherein said expandable axle comprises one or more bladders operable to expand and drive said winding core bodies. 
     
     
         16 . The winding core of  claim 15  wherein said expandable axle further comprises an inflation channel; and,
 wherein said inflation channel is utilized to introduce fluid into said one or more bladders for inflation. 
 
     
     
         17 . The winding core of  claim 16  wherein inflation of said one or more bladders reduces slippage between said axle and said winding core bodies. 
     
     
         18 . The winding core of  claim 1  wherein said winding core body is manufactured from a fiber reinforced plastic. 
     
     
         19 . A method of using a winding core comprising the steps of:
 obtaining a winding core;   obtaining an axle with expandable bladder sized to fit within the axle cavity of the winding core;   seating the axle with expandable bladder within the axle cavity;   introducing a fluid such as air into the expandable bladder securing the expandable axle within the axle cavity;   securing an end of material stock to the winding core; and,   introducing a rotary force on the axle thereby winding the material stock on the winding core.   
     
     
         20 . The method of  claim 19  further comprising the step of;
 deflating the bladder and removing the axle and bladder from the winding core.