Collapsible Spindle Assembly for Compact Packaging
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Solution Overview
Problem
Conventional paper roll support assemblies are typically packaged and shipped in a fully assembled state, leading to inefficient use of packaging materials and increased transportation costs due to 'shipping air' and excessive volume, which results in higher costs for both shipping and storage.
Innovation Solution
A collapsible spindle assembly that can be packaged in a compressed state, reducing the overall size of the packaging by allowing the spindle to be collapsed and nested within a smaller volume, utilizing a combination of outer and inner spindle members with coil springs and retainer mechanisms to maintain the collapsed state during transport and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the spindle is packaged in a fully assembled state, then the product is ready for immediate use, but the packaging volume increases leading to higher shipping and storage costs
Solution Approach 1:
The collapsible spindle is designed with nested components where the inner spindle member fits within the outer spindle member when collapsed, similar to nested dolls. This allows the spindle to be packaged in a compact state while maintaining the capability to expand to full size for use, thereby reducing packaging volume without sacrificing readiness for use.
Solution Approach 2:
The spindle transitions from a static fully assembled state to a dynamic collapsible structure that can change volume. The spring-loaded mechanism enables the spindle to be compressed for packaging and then expanded to its functional size, resolving the contradiction between compact packaging and immediate usability.
2Volume of stationary object
If the spindle is collapsed for packaging, then the packaging volume is reduced, but the device complexity increases due to additional retention mechanisms
Solution Approach 1:
The spring-loaded retainer mechanism is designed to automatically engage and disengage without external intervention. When the inner spindle member is inserted, the spring automatically locks it in the collapsed position, and rotation automatically releases it for expansion. This self-service mechanism reduces the need for complex manual retention systems while achieving compact packaging.
Solution Approach 2:
The retention function is extracted as a separate spring-loaded mechanism that can be independently designed and optimized. By separating the retention function from the overall spindle structure, the complexity is managed more effectively while achieving the volume reduction goal.
3Volume of stationary object
If the spindle components are separated for packaging, then the packaging volume is reduced, but the ease of assembly decreases
Solution Approach 1:
The spindle is segmented into the outer spindle member, inner spindle member, and spring-loaded retainer as separate components that can be packaged compactly. These segments are designed with simple geometric features that guide their assembly, allowing them to be easily put together despite being separated for packaging, thus resolving the contradiction between volume reduction and assembly ease.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces packaging material usage and storage space, achieving a 29.7% reduction in retail package volume and a 71.6% decrease in carton material area, while minimizing damage during transportation by allowing components to be nested and securely held in a compact form.
Implementation Method 1
a coil spring oriented within the outer spindle member and engaged by the proximal end of the inner spindle member to bias the inner spindle member toward extension
Data Source
AI summary
A paper roll support assembly is provided with a collapsible spindle with distal ends to be received in a pair of bracket receptacles. Product packaging is sized to receive the collapsible spindle only in a collapsed state of the spindle to minimize an overall size. The collapsible spindle is provided with an outer spindle member, an open end spaced apart from the distal end, and a cavity formed therein with a first diameter. An inner spindle member is provided with a proximal end spaced apart from the distal end with an outer diameter sized to be received within the cavity for translation and rotation relative to the outer spindle. A first retainer is oriented in the cavity in cooperation with a second retainer oriented on the inner spindle member such that extension is prevented in a first rotational orientation and extension is permitted in a second rotational orientation.