REEL

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to Japanese Patent Application No. 2024-232177 filed on Dec. 27, 2024. The entire content of the priority application is incorporated herein by reference.

TECHNICAL FIELD

The art disclosed herein relates to reels.

BACKGROUND ART

Japanese Patent Application Publication No. 2004-001950 describes a reel for use in a rebar tying tool. The reel includes a bobbin configured to be rotatably attached to the rebar tying tool about a predetermined rotational axis and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin includes a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer includes a plurality of grooves. The wire includes a bent portion which is a bend in the wire configured to engage each of the grooves and a wound portion extending from an end of the bent portion and wound around the cylindrical surface.

SUMMARY

The reel described in Japanese Patent Application Publication No. 2004-001950 prevents the wire from coming off the bobbin by the bent portion engaging in each of the grooves when the wire is fed from the bobbin. However, after the wire (specifically, the wound portion of the wire) has been used up, a user has to detach the bent portion of the wire from each of the grooves to separate the wire from the bobbin in order to discard the remaining portion of the wire and the bobbin separately. Thus, the reel can prevent the wire from coming off the bobbin but complicates the separation of the wire from the bobbin after the wire has been used up. The disclosure herein provides a technology facilitating separation of a wire from a bobbin after the wire has been used up while preventing the wire from coming off the bobbin.

A reel may comprise: a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis; and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin may comprise: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer may comprise: a slit opening to the space external to the flange and having a width greater than a diameter of the wire; and a retention wall in which the slit is formed. The wire may comprise: a retention portion located in the space external to the flange as viewed from the cylindrical surface, wherein the retention portion is a part of the wire that is shaped at least in a loop; an intermediate portion extending from an end of the retention portion and passing through the slit to reach a space internal to the flange; and a wound portion extending from an end of the intermediate portion and wound around the cylindrical surface.

A reel may comprise: a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis; and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin may comprise: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer may comprise: a slit opening to the space external to the flange and having a width greater than a diameter of the wire; and a retention wall in which the slit is formed. The wire may comprise: a retention portion located in the space external to the flange as viewed from the cylindrical surface; an intermediate portion extending from an end of the retention portion and passing through the slit to reach a space internal to the flange; and a wound portion extending from an end of the intermediate portion and wound around the cylindrical surface. A pressed portion of the wire may serve as the retention portion.

A reel may comprise: a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis; and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin may comprise: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer may comprise: a through hole having a diameter greater than a diameter of the wire; and a retention wall in which the through hole is formed. The wire may comprise: a retention portion located in the space external to the flange as viewed from the cylindrical surface; an intermediate portion extending from an end of the retention portion and passing through the through hole to reach a space internal to the flange; and a wound portion extending from an end of the intermediate portion and wound around the cylindrical surface. Any one of a knot in the wire, a twist in the wire, a pressed portion of the wire, and a loop formed by crimping two portions of the wire together may serve as the retention portion.

A method for manufacturing a reel may comprise: preparing a wire; preparing a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis, wherein the bobbin comprises: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface, and wherein the wire retainer comprises: a slit opening to the space external to the flange and having a width greater than a diameter of the wire; and a retention wall in which the slit is formed; forming a retention portion of the wire by shaping the wire at least in a loop; positioning the retention portion in the space external to the flange as viewed from the cylindrical surface; passing an intermediate portion of the wire, which extends from an end of the retention portion, through the slit; and winding a wound portion of the wire, which extends from an end of the intermediate portion, around the cylindrical surface.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a rebar tying tool 2 according to a first embodiment as viewed from the upper rear left side.

FIG. 2 is a diagram illustrating the internal structure of the rebar tying tool 2 according to the first embodiment.

FIG. 3 is a diagram illustrating a bobbin 24 according to the first embodiment with its left surface viewed in a direction angled to a rotational axis AX.

FIG. 4 is a diagram illustrating the bobbin 24 according to the first embodiment with its right surface viewed in a direction angled to the rotational axis AX.

FIG. 5 is a diagram illustrating the bobbin 24 according to the first embodiment with its left surface viewed in a direction angled to the rotational axis AX.

FIG. 6 is a diagram illustrating the bobbin 24 according to the first embodiment viewed in a direction perpendicular to the rotational axis AX.

FIG. 7 is a cross-sectional view illustrating a retention protrusion 98 and surrounding components according to the first embodiment.

FIG. 8 is a diagram illustrating a reel 22 according to the first embodiment with its left surface viewed in a direction angled to the rotational axis AX.

FIG. 9 is a diagram illustrating the left surface of the reel 22 according to the first embodiment viewed along the rotational axis AX.

FIG. 10 is a diagram illustrating the left surface of a reel 22 according to a second embodiment viewed along a rotational axis AX.

FIG. 11 is a diagram illustrating the left surface of a reel 22 according to a third embodiment viewed along a rotational axis AX.

FIG. 12 is a diagram illustrating the left surface of a reel 22 according to a fourth embodiment viewed along a rotational axis AX.

FIG. 13 is a diagram illustrating the right surface of a reel 22 according to a fifth embodiment viewed along a rotational axis AX.

DETAILED DESCRIPTION

In one aspect of the present teachings, a reel may comprise: a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis; and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin may comprise: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer may comprise: a slit opening to the space external to the flange and having a width greater than a diameter of the wire; and a retention wall in which the slit is formed. The wire may comprise: a retention portion located in the space external to the flange as viewed from the cylindrical surface, wherein the retention portion is a part of the wire that is shaped at least in a loop; an intermediate portion extending from an end of the retention portion and passing through the slit to reach a space internal to the flange; and a wound portion extending from an end of the intermediate portion and wound around the cylindrical surface.

The configuration above prevents the wire from coming off the bobbin by the retention portion engaging the retention wall during feeding of the wire from the bobbin. Further, a user can separate the wire from the bobbin after the wire (specifically, the wound portion of the wire) has been used up by pulling the retention portion in a direction away from the retention wall or by moving the retention portion so as to remove the wire from an open end of the slit. Thus, the configuration above can facilitate separation of the wire from the bobbin after the wire has been used up while preventing the wire from coming off the bobbin.

In one aspect of the present teachings, a knot in the wire may serve as the retention portion.

During feeding of the wire from the bobbin, the retention portion engaging the retention wall is subjected to a reaction force from the retention wall. This reaction force may deform the retention portion (e.g., the retention portion may give way to the force or the wire loop forming the retention portion may become undone). The deformation of the retention portion may lead to unintentional disengagement of the retention portion from the retention wall. In the configuration above, the retention portion is less likely to deform during feeding of the wire from the bobbin. Thus, unintentional disengagement of the retention portion from the retention wall can be prevented.

In one aspect of the present teachings, a twist in the wire may serve as the retention portion.

During feeding of the wire from the bobbin, the retention portion engaging the retention wall is subjected to a reaction force from the retention wall. This reaction force may deform the retention portion (e.g., the retention portion may give way to the force or the wire loop forming the retention portion may become undone). The deformation of the retention portion may lead to unintentional disengagement of the retention portion from the retention wall. In the configuration above, the retention portion is less likely to deform during feeding of the wire from the bobbin. Thus, unintentional disengagement of the retention portion from the retention wall can be prevented.

In one aspect of the present teachings, a loop formed by crimping two portions of the wire together may serve as the retention portion.

During feeding of the wire from the bobbin, the retention portion engaging the retention wall is subjected to a reaction force from the retention wall. This reaction force may deform the retention portion (e.g., the retention portion may give way to the force or the wire loop forming the retention portion may become undone). The deformation of the retention portion may lead to unintentional disengagement of the retention portion from the retention wall. In the configuration above, the retention portion is less likely to deform during feeding of the wire from the bobbin. Thus, unintentional disengagement of the retention portion from the retention wall can be prevented.

In one aspect of the present teachings, a reel may comprise: a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis; and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin may comprise: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer may comprise: a slit opening to the space external to the flange and having a width greater than a diameter of the wire; and a retention wall in which the slit is formed. The wire may comprise: a retention portion located in the space external to the flange as viewed from the cylindrical surface; an intermediate portion extending from an end of the retention portion and passing through the slit to reach a space internal to the flange; and a wound portion extending from an end of the intermediate portion and wound around the cylindrical surface. A pressed portion of the wire may serve as the retention portion.

The configuration above prevents the wire from coming off the bobbin by the retention portion engaging the retention wall during feeding of the wire from the bobbin. Further, a user can separate the wire from the bobbin after the wire (specifically, the wound portion of the wire) has been used up by pulling the retention portion in a direction away from the retention wall or by moving the retention portion so as to remove the wire from an open end of the slit. Thus, the configuration above can facilitate separation of the wire from the bobbin after the wire has been used up while preventing the wire from coming off the bobbin.

In one aspect of the present teachings, the wire retainer may comprise a protrusion protruding from the retention wall near the slit. At least a part of the retention portion may be concealed by the protrusion as viewed in a direction from an open end of the slit toward a base end of the slit.

Movement of the retention portion relative to the retention wall may lead to unintentional disengagement of the retention portion from the retention wall. In the configuration above, the protrusion prevents the retention portion from moving relative to the retention wall. Thus, unintentional disengagement of the retention portion from the retention wall can be prevented.

In one aspect of the present teachings, a first direction may be defined as a direction that is parallel to the rotational axis and from the flange toward the cylindrical surface. A second direction may be defined as a direction that is parallel to the rotational axis and from the cylindrical surface toward the flange. A base end of the slit may be offset in the first direction from a surface of the flange facing the first direction. An open end of the slit may be offset in the second direction from a surface of the flange facing the second direction.

The configuration above provides the slit with an increased depth. Therefore, even when the retention portion slightly moves relative to the retention wall, the retention portion is not disengaged from the retention wall. Thus, unintentional disengagement of the retention portion from the retention wall can be prevented.

In one aspect of the present teachings, a reel may comprise: a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis; and a wire wound around the bobbin and configured to be fed from the bobbin by the rebar tying tool. The bobbin may comprise: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface. The wire retainer may comprise: a through hole having a diameter greater than a diameter of the wire; and a retention wall in which the through hole is formed. The wire may comprise: a retention portion located in the space external to the flange as viewed from the cylindrical surface; an intermediate portion extending from an end of the retention portion and passing through the through hole to reach a space internal to the flange; and a wound portion extending from an end of the intermediate portion and wound around the cylindrical surface. Any one of a knot in the wire, a twist in the wire, a pressed portion of the wire, and a loop formed by crimping two portions of the wire together may serve as the retention portion.

The configuration above prevents the wire from coming off the bobbin by the retention portion engaging the retention wall during feeding of the wire from the bobbin. Further, a user can separate the wire from the bobbin after the wire (specifically, the wound portion of the wire) has been used up by pulling the retention portion in a direction away from the retention wall. Thus, the configuration above can facilitate separation of the wire from the bobbin after the wire has been used up while preventing the wire from coming off the bobbin.

In one aspect of the present teachings, the retention portion may be located radially inward of the cylindrical surface.

In the configuration above, a moment of inertia of the reel about the rotational axis is smaller than that in a configuration where the retention portion is located radially outward of the cylindrical surface. This facilitates rotation of the reel about the rotational axis.

In one aspect of the present teachings, a method for manufacturing a reel may comprise: preparing a wire; preparing a bobbin configured to be rotatably attached to a rebar tying tool about a predetermined rotational axis, wherein the bobbin comprises: a body including a cylindrical surface; a flange extending radially outward from an end of the cylindrical surface; a notch penetrating the flange in a thickness direction of the flange; and a wire retainer located in a space external to the flange as viewed from the cylindrical surface, and wherein the wire retainer comprises: a slit opening to the space external to the flange and having a width greater than a diameter of the wire; and a retention wall in which the slit is formed; forming a retention portion of the wire by shaping the wire at least in a loop; positioning the retention portion in the space external to the flange as viewed from the cylindrical surface; passing an intermediate portion of the wire, which extends from an end of the retention portion, through the slit; and winding a wound portion of the wire, which extends from an end of the intermediate portion, around the cylindrical surface.

The reel manufactured by the method above prevents the wire from coming off the bobbin by the retention portion engaging the retention wall during feeding of the wire from the bobbin. Further, a user can separate the wire from the bobbin after the wire (specifically, the wound portion of the wire) has been used up by pulling the retention portion in a direction away from the retention wall or by moving the retention portion so as to remove the wire from an open end of the slit. Thus, the reel manufactured by the method above can facilitate separation of the wire from the bobbin after the wire has been used up while preventing the wire from coming off the bobbin.

Representative, non-limiting examples of the present disclosure will now be described in further detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the disclosure. Furthermore, each of the additional features and teachings disclosed below may be utilized separately or in conjunction with other features and teachings to provide improved reels.

Moreover, combinations of features and steps disclosed in the following detailed description may not be necessary to practice the disclosure in the broadest sense, and are instead taught merely to particularly describe representative examples of the disclosure. Furthermore, various features of the above-described and below-described representative examples, as well as the various independent and dependent claims, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.

All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.

First Embodiment

A rebar tying tool 2 illustrated in FIG. 1 is configured to tie a plurality of rebars R with a wire W.

Configuration of Rebar Tying Tool 2

The rebar tying tool 2 comprises a body 4, a grip 6, a battery attachment part 10, and a reel holder 12. The grip 6 is a member configured to be gripped by a user. The grip 6 is located on a lower rear portion of the body 4. The grip 6 is formed integrally with the body 4. A trigger 14 for causing the rebar tying tool 2 to perform a tying operation is attached to an upper front portion of the grip 6. The battery attachment part 10 is located on a lower portion of the grip 6. The battery attachment part 10 is formed integrally with the grip 6. A battery pack B is detachably attached to the battery attachment part 10. The battery pack B is, for example, a lithium-ion battery. The reel holder 12 is located on a lower front portion of the body 4. The reel holder 12 is located forward of the grip 6. In this embodiment, the longitudinal direction of a twist mechanism 38 (see FIG. 2), which is detailed below, is termed a front-rear direction, a direction perpendicular to the front-rear direction is termed an up-down direction, and a direction perpendicular to both the front-rear direction and the up-down direction is termed a left-right direction.

The body 4 comprises, on its upper surface, a power switch 4a for turning on/off the rebar tying tool 2, a setting switch 4b for changing various settings such as a tying force of the rebar tying tool 2, and a display unit 4c for displaying information on the current settings of the rebar tying tool 2.

The reel holder 12 comprises a holder housing 16 and a cover member 18. The holder housing 16 is located on the lower front portion of the body 4 and a front portion of the battery attachment part 10. The cover member 18 is rotatably attached to the holder housing 16 about a rotation shaft 20 located in an upper portion of the holder housing 16. The user can access the inside of the holder housing 16 by opening the cover member 18 relative to the holder housing 16.

As illustrated in FIG. 2, the holder housing 16 is configured to house a reel 22. The reel 22 includes a bobbin 24 and the wire W wound around the bobbin 24. The bobbin 24 is configured to be rotatably attached to the holder housing 16 about a rotational axis AX extending in the left-right direction. The rebar tying tool 2 ties the rebars R with the wire W fed from the bobbin 24.

The rebar tying tool 2 comprises a feed mechanism 32, a guide mechanism 34, a cutting mechanism 36, a twist mechanism 38, a feed motor 40, and a twist motor 42.

The feed mechanism 32 is housed within the lower front portion of the body 4. The feed mechanism 32 comprises a feed roller 44. The feed roller 44 is coupled to the feed motor 40 via a speed reducer (not illustrated). When the feed motor 40 rotates, the feed roller 44 also rotates. By rotating in the forward direction, the feed roller 44 feeds the wire W out from the bobbin 24 forward and upward toward the guide mechanism 34. By rotating in the reverse direction, the feed roller 44 pulls the wire W back toward the bobbin 24.

The guide mechanism 34 is located on a front portion of the body 4. The guide mechanism 34 comprises an upper curl guide 46 and a lower curl guide 48. The rebars R are positioned between the upper curl guide 46 and the lower curl guide 48 for tying. The wire W fed out by the feed roller 44 is first guided into the upper curl guide 46 and passes through the interior of the upper curl guide 46 from rear to front. While the wire W passes through the upper curl guide 46, a downward curl is imparted to the wire W by the upper curl guide 46. After passing through the upper curl guide 46, the wire W is guided into the lower curl guide 48 and passes through the interior of the lower curl guide 48 from front to rear. Thereafter, the wire W proceeds rearward and upward. Thereby, the wire W is wound around the rebars R.

The cutting mechanism 36 is housed within a lower portion of the body 4. The cutting mechanism 36 comprises a cutter (not illustrated) to cut the wire W extending between the feed mechanism 32 and the guide mechanism 34. The cutter cuts the wire W in coordination with the twist mechanism 38 detailed below.

The twist mechanism 38 is housed within the body 4. The twist mechanism 38 comprises a sleeve unit 50 and a grip unit 52. The sleeve unit 50 is coupled to the twist motor 42 via a speed reducer (not illustrated). When the twist motor 42 rotates, the sleeve unit 50 moves in the front-rear direction or rotates about a rotational axis extending in the front-rear direction. The grip unit 52 is located in a front portion of the twist mechanism 38. When the sleeve unit 50 moves forward, the grip unit 52 grips a first portion of the wire W around the rebars R. When the sleeve unit 50 moves further forward, the grip unit 52 grips a second portion of the wire W around the rebars R, which is closer to the base end of the wire W than the first portion is. When the sleeve unit 50 rotates in the forward direction after the wire W is cut by the cutting mechanism 36, the grip unit 52 rotates integrally with the sleeve unit 50. The wire W is thereby twisted by the grip unit 52. As a result, the rebars R are tied with the wire W. When the sleeve unit 50 rotates in the reverse direction, the grip unit 52 releases the wire W and the sleeve unit 50 moves rearward.

Every time the trigger 14 is manipulated, the rebar tying tool 2 performs a tying operation including a series of actions of: feeding the wire W out from the bobbin 24 by the feed mechanism 32, winding the wire W around the rebars R by the guide mechanism 34, gripping the first portion of the wire W by the twist mechanism 38, pulling the wire W back toward the bobbin 24 by the feed mechanism 32, gripping the second portion of the wire W by the twist mechanism 38, cutting the wire W by the cutting mechanism 36, and twisting the wire W by the twist mechanism 38.

Configuration of Reel 22

As illustrated in FIG. 3, the bobbin 24 comprises a body 64 including a cylindrical surface 62 extending in the left-right direction, a left flange 66 extending radially outward from the left end of the cylindrical surface 62, and a right flange 68 extending radially outward from the right end of the cylindrical surface 62. The wire W is wound around the cylindrical surface 62. The left flange 66 limits leftward movement of the wire W wound on the cylindrical surface 62. The right flange 68 limits rightward movement of the wire W wound on the cylindrical surface 62. In this embodiment, a space expanding radially outward from the cylindrical surface 62 (i.e., a space between a right surface 66a of the left flange 66 and a left surface 68a of the right flange 68) is termed “space internal to the left flange 66” or “space internal to the right flange 68”, a space behind the left flange 66 as viewed from the cylindrical surface 62 is termed “space external to the left flange 66”, and a space behind the right flange 68 as viewed from the cylindrical surface 62 is termed “space external to the right flange 68”.

The body 64 comprises an outer cylindrical portion 72 defining the cylindrical surface 62, an inner cylindrical portion 74 located inward of the outer cylindrical portion 72, a connection rib 76 connecting the outer cylindrical portion 72 to the inner cylindrical portion 74, and a partition wall 78 partitioning a space internal to the inner cylindrical portion 74. The partition wall 78 expands perpendicular to the rotational axis AX. The partition wall 78 partitions the space internal to the inner cylindrical portion 74 into a left internal space 80 and a right internal space 82 (see FIG. 4). The left internal space 80 is open to the space external to the left flange 66.

A first left notch 84 and a second left notch 86 are formed in the left flange 66. The first left notch 84 penetrates the left flange 66 in its thickness direction, extends from the outer peripheral edge of the flange 66 to the inner cylindrical portion 74, and connects to a slit 96 detailed below. The second left notch 86 penetrates the left flange 66 in its thickness direction and is recessed from the outer peripheral edge of the left flange 66. A right notch 88 is formed in the right flange 68. The right notch 88 penetrates the right flange 68 in its thickness direction and extends from the outer peripheral edge of the right flange 68 to the outer cylindrical portion 72. The right notch 88 is located to face the left flange 66 in the left-right direction.

As illustrated in FIG. 4, the right internal space 82 is open to the space external to the right flange 68. When the bobbin 24 is attached to the rebar tying tool 2 (see FIG. 1), a support cylinder (not illustrated) of the holder housing 16 (see FIG. 1) is rotatably received in the right internal space 82. Similarly, a support cylinder (not illustrated) of the cover member 18 (see FIG. 1) is rotatably received in the left internal space 80 (see FIG. 3). The bobbin 24 is thereby rotatably supported in the rebar tying tool 2.

An identification protrusion 90 protruding rightward is formed on a right surface 78a of the partition wall 78. The length of the identification protrusion 90 varies depending on the type of reel 22. Thus, the type of reel 22 can be identified based on the length of the identification protrusion 90. The types of reel 22 are classified, for example, according to the diameter of the wire W, the material of the wire W, the presence or absence of a coating on the wire W and the material of that coating, and the presence or absence of surface treatment on the wire W and the nature of the surface treatment. The rebar tying tool 2 (see FIG. 1) comprises a reel-type detector (not illustrated) configured to detect the type of reel 22 by detecting the length of the identification protrusion 90 of a reel 22 attached to the reel holder 12 (see FIG. 1).

As illustrated in FIG. 5, a wire retainer 92 is formed on a part of the inner cylindrical portion 74 that is exposed to the space external to the left flange 66. The wire retainer 92 comprises a retention wall 94, a slit 96, and two retention protrusions 98. The retention wall 94 is a part of the inner cylindrical portion 74. The retention wall 94 extends leftward from a left surface 78b of the partition wall 78. The slit 96 penetrates the retention wall 94 in its thickness direction. The slit 96 is open to the space external to the left flange 66. The slit 96 extends linearly along the left-right direction from a base end 96a at the base of the retention wall 94 (i.e., on the left surface 78b of the partition wall 78) to an open end 96b at the end of the retention wall 94 (i.e., the left end of the inner cylindrical portion 74). As illustrated in FIG. 6, the base end 96a of the slit 96 is offset rightward from the right surface 66a of the left flange 66. The open end 96b of the slit 96 is offset leftward from a left surface 66b of the left flange 66. The depth of the slit 96 (i.e., the length of the slit 96 in the left-right direction) is, for example, in the range of 5 mm to 15 mm, and in this embodiment, the depth is 12 mm. The width of the slit 96 is substantially constant from the base end 96a to the open end 96b and is larger than the diameter of the wire W. The diameter of the wire W is, for example, in the range of 0.5 mm to 2.5 mm, and in this embodiment, the diameter is 1.6 mm. The width of the slit 96 is, for example, in the range of 0.6 mm to 5.0 mm, and in this embodiment, the width is 3.1 mm.

As illustrated in FIG. 5, the retention protrusions 98 protrude from the retention wall 94 near the slit 96. One of the retention protrusions 98 is smoothly continuous from one side of the slit 96. The other retention protrusion 98 is smoothly continuous from the other side of the slit 96. As illustrated in FIG. 7, a right surface 98a of each retention protrusion 98 is spaced leftward from the left surface 78b of the partition wall 78. The right surface 98a of each retention protrusion 98 is a flat surface angled to the left surface 78b of the partition wall 78. The right surface 98a of each retention protrusion 98 is angled such that the farther it is from the retention wall 94, the farther it is from the left surface 78b of the partition wall 78. Thus, a gap 100 between the partition wall 78 and each retention protrusion 98 is decreased toward the retention wall 94. A left surface 98b of each retention protrusion 98 extends such that the farther it is from the retention wall 94, the closer it is to the left surface 78b of the partition wall 78. The retention protrusions 98 are located so as not to interfere with the support cylinder (not illustrated) of the cover member 18 received in the left internal space 80. Further, through holes 102 are formed in portions of the partition wall 78 that faces the retention protrusions 98. The through holes 102 penetrate the partition wall 78 in the left-right direction. The through holes 102 are larger than the diameter of the wire W.

As illustrated in FIG. 8, the wire W wound on the bobbin 24 comprises a retention portion 112 located in the space external to the left flange 66, an intermediate portion 114 extending from an end of the retention portion 112 and passing through the slit 96 to reach the space internal to the left flange 66, a wound portion 116 extending from an end of the intermediate portion 114 and wound around the cylindrical surface 62, and a leading end portion 118 extending from an end of the wound portion 116 and passing through the first left notch 84 to reach the space external to the left flange 66.

In this embodiment, a knot 120 formed near the base end of the wire W serves as the retention portion 112. The knot 120 is not limited to the one illustrated in FIG. 8 and may be any one of a Stevedore knot, a figure-eight knot, a bowline knot, a butterfly knot, a handcuff knot, a lasso knot, a bowline on the knot, a bow knot, an overhand knot, a rabbit knot, and an Ashley stopper knot. The retention portion 112 is held in the gap 100 between the partition wall 78 and the retention protrusions 98.

As illustrated in FIG. 9, the retention portion 112, as viewed in the direction from the open end 96b of the slit 96 toward the base end 96a (in the right direction), is partially concealed by the retention protrusions 98. Further, the retention portion 112 is located radially inward of the cylindrical surface 62 and within the left internal space 80. The retention portion 112 is located so as not to interfere with the support cylinder (not illustrated) of the cover member 18 received in the left internal space 80. Further, the retention portion 112 cannot pass through the slit 96. The retention portion 112 engages the retention wall 94 during feeding of the wire W from the bobbin 24, thereby preventing the wire W from coming off the bobbin 24.

In a manufacture of the reel 22 illustrated in FIG. 8, the bobbin 24 and the wire W are prepared first. Then, the intermediate portion 114 is passed through the slit 96 to place a portion of the wire W near its base end in the left internal space 80. Next, the retention portion 112 is formed in the portion of the wire W near its base end. In this embodiment, the knot 120 is formed near the base end of the wire W. Then, the retention portion 112 is pushed into the gap 100 between the partition wall 78 and the retention protrusions 98 to hold the retention portion 112 in the gap 100. Next, a portion of the wire W that is closer to the leading end of the wire W than the intermediate portion 114 is wound around the cylindrical surface 62 to form the wound portion 116. Then, a portion of the wire W that is closer to the leading end of the wire W than the wound portion 116 is passed through the first left notch 84 to be positioned at the second left notch 86 in the space external to the left flange 66 and radially outward of the inner cylindrical portion 74. Finally, the wire W is cut at the second left notch 86 to form the leading end portion 118. In this way, the reel 22 is manufactured.

In order to separate the wire W from the bobbin 24 after the wire W (specifically, the wound portion 116) has been used up, the retention portion 112 is first pulled out from the gap 100 between the partition wall 78 and the retention protrusions 98. Then, the retention portion 112 is pulled away from the retention wall 94 or moved leftward so as to remove the wire W from the open end 96b of the slit 96. In this way, the wire W is separated from the bobbin 24.

Features of First Embodiment

The reel 22 according to the first embodiment comprises the bobbin 24 configured to be rotatably attached to the rebar tying tool 2 about the predetermined rotational axis AX and the wire W wound around the bobbin 24 and configured to be fed from the bobbin 24 by the rebar tying tool 2. The bobbin 24 comprises the body 64 including the cylindrical surface 62, the left flange 66 (an example of flange) extending radially outward from an end of the cylindrical surface 62, the first left notch 84 (an example of notch) penetrating the left flange 66 in the thickness direction of the left flange 66, and the wire retainer 92 located in the space external to the left flange 66 as viewed from the cylindrical surface 62. The wire retainer 92 comprises the slit 96 opening to the space external to the left flange 66 and having a width greater than the diameter of the wire W, and the retention wall 94 in which the slit 96 is formed. The wire W comprises the retention portion 112 located in the space external to the left flange 66 as viewed from the cylindrical surface 62, wherein the retention portion 112 is a part of the wire W that is shaped at least in a loop; the intermediate portion 114 extending from an end of the retention portion 112 and passing through the slit 96 to reach the space internal to the left flange 66; and the wound portion 116 extending from an end of the intermediate portion 114 and wound around the cylindrical surface 62.

The configuration above prevents the wire W from coming off the bobbin 24 by the retention portion 112 engaging the retention wall 94 during feeding of the wire W from the bobbin 24. Further, the user can separate the wire W from the bobbin 24 after the wire W (specifically, the wound portion 116 of the wire W) has been used up by pulling the retention portion 112 in a direction away from the retention wall 94 or by moving the retention portion 112 so as to remove the wire W from the open end 96b of the slit 96. Thus, the configuration above can facilitate separation of the wire W from the bobbin 24 after the wire W has been used up while preventing the wire W from coming off the bobbin 24.

The knot 120 in the wire W serves as the retention portion 112.

During feeding of the wire W from the bobbin 24, the retention portion 112 engaging the retention wall 94 is subjected to a reaction force from the retention wall 94. This reaction force may deform the retention portion 112 (e.g., the retention portion 112 may give way to the force or the loop of the wire W forming the retention portion 112 may become undone). The deformation of the retention portion 112 may lead to unintentional disengagement of the retention portion 112 from the retention wall 94. In the configuration above, the retention portion 112 is less likely to deform during feeding of the wire W from the bobbin 24. Thus, unintentional disengagement of the retention portion 112 from the retention wall 94 can be prevented.

The wire retainer 92 comprises retention protrusions 98 (an example of protrusion) protruding from the retention wall 94 near the slit 96. At least a part of the retention portion 112 is concealed by the retention protrusions 98 as viewed in the direction from the open end 96b of the slit 96 toward the base end 96a of the slit 96.

Movement of the retention portion 112 relative to the retention wall 94 may lead to unintentional disengagement of the retention portion 112 from the retention wall 94. In the configuration above, the retention protrusions 98 prevent the retention portion 112 from moving relative to the retention wall 94. Thus, unintentional disengagement of the retention portion 112 from the retention wall 94 can be prevented.

A first direction is defined as a direction that is parallel to the rotational axis AX and from the left flange 66 toward the cylindrical surface 62 (i.e., the right direction). A second direction is defined as a direction that is parallel to the rotational axis AX and from the cylindrical surface 62 toward the left flange 66 (i.e., the left direction). The base end 96a of the slit 96 is offset in the first direction from the right surface 66a of the left flange 66 (an example of surface of the flange facing the first direction). The open end 96b of the slit 96 is offset in the second direction from the left surface 66b of the left flange 66 (an example of surface of the flange facing the second direction).

The configuration above provides the slit 96 with an increased depth. Therefore, even when the retention portion 112 slightly moves relative to the retention wall 94, the retention portion 112 is not disengaged from the retention wall 94. Thus, unintentional disengagement of the retention portion 112 from the retention wall 94 can be prevented.

The retention portion 112 is located radially inward of the cylindrical surface 62.

In the configuration above, a moment of inertia of the reel 22 about the rotational axis AX is smaller than that in a configuration where the retention portion 112 is located radially outward of the cylindrical surface 62. This facilitates rotation of the reel 22 about the rotational axis AX.

The method for manufacturing the reel 22 comprises preparing the wire W; preparing the bobbin 24 configured to be rotatably attached to the rebar tying tool 2 about the predetermined rotational axis AX, wherein the bobbin 24 comprises the body 64 including the cylindrical surface 62, the left flange 66 extending radially outward from an end of the cylindrical surface 62, the first left notch 84 penetrating the left flange 66 in the thickness direction of the left flange 66, and the wire retainer 92 located in the space external to the left flange 66 as viewed from the cylindrical surface 62, and wherein the wire retainer 92 comprises the slit 96 opening to the space external to the left flange 66 and having a width greater than the diameter of the wire W and the retention wall 94 in which the slit 96 is formed; forming the retention portion 112 on the wire W by shaping the wire W at least in a loop; positioning the retention portion 112 in the space external to the left flange 66 as viewed from the cylindrical surface 62; passing the intermediate portion 114 of the wire W, which extends from an end of the retention portion 112, through the slit 96; and winding the wound portion 116 of the wire W, which extends from an end of the intermediate portion 114, around the cylindrical surface 62.

The reel 22 manufactured by the method above prevents the wire W from coming off the bobbin 24 by the retention portion 112 engaging the retention wall 94 during feeding of the wire W from the bobbin 24. Further, the user can separate the wire W from the bobbin 24 after the wire W (specifically, the wound portion 116 of the wire W) has been used up by pulling the retention portion 112 in a direction away from the retention wall 94 or by moving the retention portion 112 so as to remove the wire W from the open end 96b of the slit 96. Thus, the reel 22 manufactured by the method above can facilitate separation of the wire W from the bobbin 24 after the wire W has been used up while preventing the wire W from coming off the bobbin 24.

Second Embodiment

As illustrated in FIG. 10, a reel 22 according to a second embodiment is different from the reel 22 according to the first embodiment in that a twist 130 serves as the retention portion 112 instead of the knot 120 (see FIG. 9). The twist 130 is formed by shaping a portion of the wire W near its base end in a closed loop and twisting the wire W at the intersection of the wire W. The twist 130 is pushed into the gap 100 (see FIG. 7) between the partition wall 78 and the retention protrusions 98 and held therein.

Feature of Second Embodiment

In the second embodiment, the twist 130 in the wire W serves as the retention portion 112.

During feeding of the wire W from the bobbin 24, the retention portion 112 engaging the retention wall 94 is subjected to a reaction force from the retention wall 94. This reaction force may deform the retention portion 112 (e.g., the retention portion 112 may give way to the force or the loop of wire W forming the retention portion 112 may become undone). The deformation of the retention portion 112 may lead to unintentional disengagement of the retention portion 112 from the retention wall 94. In the configuration above, the retention portion 112 is less likely to deform during feeding of the wire W from the bobbin 24. Thus, unintentional disengagement of the retention portion 112 from the retention wall 94 can be prevented.

Third Embodiment

As illustrated in FIG. 11, a reel 22 according to a third embodiment is different from the reel 22 according to the first embodiment in that a pressed portion 140 serves as the retention portion 112 instead of the knot 120 (see FIG. 9). The pressed portion 140 is formed by flattening a portion of the wire W near its base end. The pressed portion 140 is pushed into the gap 100 (see FIG. 7) between the partition wall 78 and the retention protrusion 98 and held therein.

Features of Third Embodiment

The reel 22 according to the third embodiment comprises the bobbin 24 configured to be rotatably attached to the rebar tying tool 2 about the predetermined rotational axis AX and the wire W wound around the bobbin 24 and configured to be fed from the bobbin 24 by the rebar tying tool 2. The bobbin 24 comprises the body 64 including the cylindrical surface 62, the left flange 66 (an example of flange) extending radially outward from an end of the cylindrical surface 62, the first left notch 84 (an example of notch) penetrating the left flange 66 in the thickness direction of the left flange 66, and the wire retainer 92 located in the space external to the left flange 66 as viewed from the cylindrical surface 62. The wire retainer 92 comprises the slit 96 opening to the space external to the left flange 66 and having a width greater than the diameter of the wire W and the retention wall 94 in which the slit 96 is formed. The wire W comprises the retention portion 112 located in the space external to the left flange 66 as viewed from the cylindrical surface 62, the intermediate portion 114 extending from an end of the retention portion 112 and passing through the slit 96 to reach the space internal to the left flange 66, and the wound portion 116 extending from an end of the intermediate portion 114 and wound around the cylindrical surface 62. The pressed portion 140 of the wire W serves as the retention portion 112.

The configuration above prevents the wire W from coming off the bobbin 24 by the retention portion 112 engaging the retention wall 94 during feeding of the wire W from the bobbin 24. Further, the user can separate the wire W from the bobbin 24 after the wire W (specifically, the wound portion 116 of the wire W) has been used up by pulling the retention portion 112 in a direction away from the retention wall 94 or by moving the retention portion 112 so as to remove the wire W from the open end 96b of the slit 96. Thus, the configuration above can facilitate separation of the wire W from the bobbin 24 after the wire W has been used up while preventing the wire W from coming off the bobbin 24.

Fourth Embodiment

As illustrated in FIG. 12, a reel 22 according to a fourth embodiment is different from the reel 22 according to the first embodiment in that a loop 150 formed by crimping two portions of the wire W together serves as the retention portion 112 instead of the knot 120 (see FIG. 9). The two portions of the wire W are crimped together with a sleeve 152 bundling the two portions of the wire W. The two portions of the wire W may be crimped together without the use of sleeve 152. The loop 150 is pushed into the gap 100 (see FIG. 7) between the partition wall 78 and the retention protrusions 98 and held therein.

Feature of Fourth Embodiment

In the fourth embodiment, the loop 150 formed by crimping two portions of the wire W together serves as the retention portion 112.

During feeding of the wire W from the bobbin 24, the retention portion 112 engaging the retention wall 94 is subjected to a reaction force from the retention wall. This reaction force may deform the retention portion 112 (e.g., the retention portion 112 may give way to the force or the loop of wire W forming the retention portion 112 may become undone). The deformation of the retention portion 112 may lead to unintentional disengagement of the retention portion 112 from the retention wall 94. In the configuration above, the retention portion 112 is less likely to deform during feeding of the wire W from the bobbin 24. Thus, unintentional disengagement of the retention portion 112 from the retention wall 94 can be prevented.

Fifth Embodiment

As illustrated in FIG. 13, a reel 22 according to a fifth embodiment is different from the reel 22 according to the first embodiment in that the retention portion 112 is located in the right internal space 82 and the intermediate portion 114 passes through one of the through holes 102 and the slit 96. The retention portion 112 is located so as not to interfere with the support cylinder (not illustrated) of the holder housing 16 (see FIG. 1) received in the right internal space 82. Further, the retention portion 112 cannot pass through the through holes 102. The retention portion 112 prevents the wire W from coming off the bobbin 24 during feeding of the wire W from the bobbin 24 by engaging the right surface 78a of the partition wall 78. In the fifth embodiment, the wire W can be separated from the bobbin 24 after the wire W (specifically, the wound portion 116) has been used up by pulling the retention portion 112 in a direction away from the right surface 78a of the partition wall 78 (i.e., in the right direction).

The retention portion 112 may be any one of the twist 130 described in connection with the second embodiment (see FIG. 10), the pressed portion 140 described in connection with the third embodiment (see FIG. 11), and the loop 150 described in connection with the fourth embodiment (see FIG. 12), instead of the knot 120.

Features of Fifth Embodiment

The reel 22 according to the fifth embodiment comprises the bobbin 24 configured to be rotatably attached to the rebar tying tool 2 about the predetermined rotational axis AX and the wire W wound around the bobbin 24 and configured to be fed from the bobbin 24 by the rebar tying tool 2. The bobbin 24 comprises the body 64 including the cylindrical surface 62, the left flange 66 (an example of flange) extending radially outward from an end of the cylindrical surface 62, the first left notch 84 (an example of notch) penetrating the left flange 66 in the thickness direction of the left flange 66, and the wire retainer 92 located in the space external to the left flange 66 as viewed from the cylindrical surface 62. The wire retainer 92 comprises the through holes 102 which are greater than the diameter of the wire W and the partition wall 78 in which the through holes 102 are formed. The wire W comprises the retention portion 112 located in the space external to the left flange 66 as viewed from the cylindrical surface 62, the intermediate portion 114 extending from an end of the retention portion 112 and passing through one of the through holes 102 to reach the space internal to the left flange 66, and the wound portion 116 extending from an end of the intermediate portion 114 and wound around the cylindrical surface 62. One of the knot 120 in the wire W, the twist 130 in the wire W, the pressed portion 140 of the wire W, and the loop 150 formed by crimping two portions of the wire W together serves as the retention portion 112.

The configuration above prevents the wire W from coming off the bobbin 24 by the retention portion 112 engaging the partition wall 78 during feeding of the wire W from the bobbin 24. Further, the user can separate the wire W from the bobbin 24 after the wire W (specifically, the wound portion 116 of the wire W) has been used up by pulling the retention portion 112 in a direction away from the partition wall 78. Thus, the configuration above can facilitate separation of the wire W from the bobbin 24 after the wire W has been used up while preventing the wire W from coming off the bobbin 24.

Variants

(See FIG. 5.) The wire retainer 92 may not comprise the retention protrusions 98. That is, the bobbin 24 may not be configured to hold the retention portion 112 near the slit 96.

(See FIG. 6.) The base end 96a of the slit 96 may not be offset rightward from the right surface 66a of the left flange 66. That is, the base end 96a of the slit 96 may be offset leftward from the right surface 66a of the left flange 66.

(See FIG. 9.) At least a part of the retention portion 112 may be located radially outward of the cylindrical surface 62.

In the manufacturing method of the reel 22, the step of forming the retention portion 112 in the wire W, the step of positioning the retention portion 112 in the space external to the left flange 66 as viewed from the cylindrical surface 62, and the step of passing the intermediate portion 114 of the wire W through the slit 96 may be interchangeable. As described in the embodiment, these three steps may be performed in the following order: the step of passing the intermediate portion 114, the step of forming the retention portion 112, and the step of positioning the retention portion 112. Alternatively, these three steps may be performed in the following order: the step of forming the retention portion 112, the step of positioning the retention portion 112, and the step of passing the intermediate portion 114.