Double-Wall Hub Reel Design for Damage Resistance
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Solution Overview
Problem
Existing reels for storing and dispensing clip lines are prone to damage due to their complex designs, which increase production costs and reduce their ability to withstand repeated use and transport without sustaining damage.
Innovation Solution
A reel design featuring two identical halves with a double-wall hub structure, where each half has at least one hub segment with a double-wall design, and recesses and protrusions for secure connection, reducing production complexity and enhancing strength while allowing for easy assembly and potential replacement of defective parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex double-wall hub design is used, then the reel's strength and rigidity are improved, but the device complexity and production costs increase
Solution Approach 1:
The reel is divided into two identical reel halves that are assembled together to form the complete reel. Each reel half contains a simplified single-wall hub structure, and when assembled, they create the functional double-wall hub configuration. This segmentation allows each half to be manufactured separately with simpler tooling while achieving the strength benefits of a double-wall design through the combined structure.
Solution Approach 2:
Two identical reel halves with single-wall hubs are combined through assembly to form the functional double-wall hub structure. The merging of these two simpler components achieves the rigidity and strength of a complex double-wall design without requiring complex manufacturing processes for each individual component.
2Ease of manufacture
If a simple hub design is used, then the production effort is reduced, but the reel is more prone to damage during transport and use
Solution Approach 1:
The reel is segmented into two identical halves that can be manufactured using simpler, less expensive tooling. Each half contains a simplified hub structure that is easier to manufacture, yet when assembled together, the combined structure provides the damage resistance and reliability needed for withstanding transport and repeated use.
Solution Approach 2:
The double-wall hub structure is implemented only in specific segments or regions where maximum strength is needed, rather than throughout the entire hub. This allows the reel to have enhanced reliability in critical areas while maintaining simpler and more cost-effective manufacturing in other areas.
3Ease of manufacture
If identical reel halves are used, then the production complexity is reduced through standardized manufacturing, but the connection between halves must be precisely designed
Solution Approach 1:
The reel is divided into two identical reel halves that can be manufactured using the same tooling and processes, enabling standardized production and reduced manufacturing complexity. The segmentation into identical modules simplifies inventory management and assembly while the connection features are designed to be straightforward and robust.
Solution Approach 2:
While the overall reel halves are symmetric and identical, asymmetric connection features such as protrusions and recesses are incorporated at the assembly interface. These asymmetric elements ensure proper orientation and secure connection between the two halves during assembly, preventing incorrect installation while maintaining standardized manufacturing of the identical halves.
Data Source
AI summary
The present invention relates to a reel for storing and dispensing a winding material wound on the reel. The reel comprises a hub and side walls each disposed at the axial end faces of the hub and protruding past the outer circumferential surface of the hub in an approximately radial direction, the storage space defined by the surfaces of the side walls facing toward each other and the outer circumferential surface of the hub and surrounding the hub serving for receiving the winding material. The hub is at least double-walled in design, having a first hub wall and having a second hub wall spaced radially apart from the first hub wall. Moreover, the reel is formed of two reel halves identical in design.