Induction bonded reel

1 . A reel comprising:

a core;

a first flange affixed to a first end of the core;

a second flange affixed to a second opposite end of the core; and

a first bonded joint connecting the first flange to the core, the first bonded joint including a first susceptor material arranged between the first flange and the first end of the core,

wherein the first flange and the first end of the core are bonded around the first susceptor material;

wherein the first flange comprises a core nest region defining an annular channel in which the first end of the core is connected to the first flange via the first bonded joint; and

further comprising a plurality of stand-off tabs extending between a base surface of the annular channel and the first end of the core to define an axial distance between at least a portion of the first end of the core and the base surface of the annular channel.

2 . The reel of claim 1 , wherein:

the first bonded joint further comprises a resin material in which the first susceptor material is embedded, and

the resin material is materially bonded to a first material of the core and to a second material of the first flange.

3 . The reel of claim 1 , wherein the first susceptor material is arranged at least partially between a base of the annular channel and the first end of the core.

4 . The reel of claim 3 , wherein the first susceptor material is partially interposed between an inner wall of the annular channel and an inner radial surface of the core.

5 . The reel of claim 4 , wherein a first distance between an outer wall of the annular channel and an outer radial surface of the core is less than a second distance between an inner wall of the annular channel and an inner radial surface of the core.

6 . The reel of claim 4 , wherein the first susceptor material further comprises a first portion arranged between an end surface of the core and a base surface of the annular channel, a second portion interposed between an inner side surface of the core and an inner wall of the annular channel, and a third portion interposed between the inner side surface of the core and the inner wall of the annular channel, the second portion being interposed axially between the first and third portions and the second portion having a smaller radial thickness than the third portion.

7 . The reel of claim 4 , wherein the first flange further comprises a plurality of wedge-shaped portions protruding outwardly from an inner wall of the annular channel, the wedge-shaped portions configured to urge the first end of the core radially outwardly toward an outer wall of the annular channel.

8 . The reel of claim 1 , wherein a first material of the core is materially bonded to a second material of the first flange at the first susceptor material.

9 . The reel of claim 8 , wherein the first susceptor material comprises at least one wire arranged in the annular channel and around which the first flange and the first end of the core are bonded to one another.

10 . The reel of claim 8 , wherein the first susceptor material comprises a wire mesh arranged in the annular channel and around which the first flange and the first end of the core are bonded to one another.

11 . The reel of claim 1 , wherein the first flange includes a plurality of wedge-shaped cutouts defined into an inner wall of the annular channel, and the first susceptor material is arranged partially in the plurality of wedge-shaped cutouts.

12 . The reel of claim 1 , further comprising:

a second bonded joint connecting the second flange to the second end of the core, the second bonded joint including a second susceptor arranged between the second flange and the second end of the core,

wherein the second flange and the second end of the core are bonded around the second susceptor material.

13 . The reel of claim 1 , wherein the stand-off tabs are formed on the base surface of the annular channel.

14 . A reel comprising:

a core;

a first flange affixed to a first end of the core;

a second flange affixed to a second opposite end of the core; and

a first bonded joint connecting the first flange to the core, the first bonded joint including a first susceptor material arranged between the first flange and the first end of the core, wherein the first flange and the first end of the core are bonded around the first susceptor material;

wherein the first flange comprises a core nest region defining an annular channel in which the first end of the core is connected to the first flange via the first bonded joint; and

wherein the first flange defines a plurality of notches extending radially from the annular channel and in which the first susceptor material is partially arranged.

15 . A method of producing a reel comprising:

interposing a first susceptor material between a first flange and a first end of a core of the reel; and

applying a magnetic field to the first susceptor material so as to excite the first susceptor material and increase a temperature of the first susceptor material, forming a first bonded joint around the first susceptor at which the first flange is bonded to the first end of the core;

applying pressure urging the core and the first flange together while applying the magnetic field;

wherein the interposing of the first susceptor material includes inserting the first susceptor material and the first end of the core in an annular channel defined in the first flange;

wherein the first susceptor material is embedded in a bonding material that includes plastic;

wherein applying the magnetic field to the first susceptor material increases the temperature of the first susceptor material sufficiently to liquefy at least a portion of the plastic of the bonding material to form a liquefied portion; and

wherein applying the pressure urging the core and the first flange together while applying the magnetic field displaces at least some of the liquefied portion such that the at least some of liquefied portion moves along at least one side wall of the core in the annular channel.

16 . The method of claim 15 , further comprising:

interposing a second susceptor material between a second flange and a second opposite end of the core; and

applying the magnetic field to the second susceptor material so as to excite the second susceptor material and increase a temperature of the second susceptor material forming a second bonded joint around the second susceptor material at which the second flange is bonded to the second end of the core.

17 . The method of claim 16 , wherein the applying of the magnetic field to the first susceptor material and the applying of the magnetic field to the second susceptor material occur at least partially simultaneously.

18 . The method of claim 17 , further comprising:

applying axial pressure to the first and second flanges during the application of the magnetic field to the first and second susceptor materials to urge the first and second flanges toward one another.