FIG. 8 Wire Payoff via Inner Diameter Extraction
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Solution Overview
Problem
Existing wire and cable packaging solutions are cumbersome, prone to damage, and require additional equipment for payoff, leading to tangles and increased pulling force, especially in wet conditions.
Innovation Solution
A clamshell-configured wire and cable package with a FIG. 8 coiled pattern and embedded payoff port allows wire extraction from the inner diameter along the same axis as payoff, eliminating the need for reel rotation and additional support equipment, using durable and water-resistant materials like PVC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wire is paid off from the outer diameter of a traditional reel or spool, then the wire can be dispensed, but the reel must rotate during payoff requiring additional support equipment and generating tangles and overruns
Solution Approach 1:
The patent inverts the traditional wire payoff approach by winding wire in a FIG. 8 pattern around a central payoff tube and extracting wire from the inner diameter rather than the outer diameter. This inversion eliminates the need for reel rotation during payoff, removing the requirement for jack stands and shafts, and preventing tangles and overruns that occur with traditional outer diameter payoff methods
Solution Approach 2:
The patent extracts the payoff function from the traditional rotating reel system by embedding a stationary payoff tube within the FIG. 8 coil structure. The wire is extracted from the inner diameter of the coil through this embedded tube, separating the wire extraction function from the reel rotation mechanism, thereby eliminating the need for additional support equipment
2Quantity of substance
If traditional reels or spools are used for wire winding, then wire can be stored and transported, but the reels are cumbersome and difficult to carry due to lack of handles and significant weight
Solution Approach 1:
The patent replaces traditional rigid wooden or plastic reels with a flexible FIG. 8 coil structure that can be compactly wound and contained. The wire itself forms the structural element, eliminating the need for heavy reel bodies, while maintaining full wire storage capacity. The flexible nature of the coiled structure allows for easier handling and transport without compromising storage capability
3Ease of operation
If traditional wooden reels are used in wet conditions, then wire can be paid off, but the wood absorbs water acting as a wick and becomes heavier
Solution Approach 1:
The patent eliminates the use of traditional wooden or plastic reel materials that are susceptible to water absorption by using a FIG. 8 coil structure where the wire itself serves as the packaging and payoff mechanism. This approach removes the vulnerable intermediate material layer, preventing water wicking and associated weight increase while maintaining payoff functionality in wet conditions
4Quantity of substance
If traditional reels or spools are used for wire winding, then wire can be stored, but the reels are prone to damage such as splintering or shattering if dropped
Solution Approach 1:
The patent merges the wire storage function with a durable FIG. 8 coil structure that eliminates traditional vulnerable reel materials. The wire itself is arranged in a FIG. 8 pattern that provides structural integrity, combining the storage function with inherent durability. This merged structure resists splintering and shattering that plague traditional wooden and plastic reels when dropped, while maintaining full wire storage capability
5Ease of operation
If wire is extracted from the outer diameter of a coil, then payoff can occur, but additional pulling force is required to rotate the entire weight of the reel and its contents
Solution Approach 1:
The patent inverts the extraction point from the outer diameter to the inner diameter of the FIG. 8 coil structure. By extracting wire from the center through the embedded payoff tube rather than from the outer edge, the system eliminates the need to overcome the rotational inertia and weight of the entire reel assembly, dramatically reducing the pulling force required for wire extraction
Data Source
AI summary
An apparatus for the transportation and payoff of coiled wire and cable, the apparatus comprising a clamshell package, an inner void formed by the clamshell package, the inner void comprising a compartment within for containing coiled wire and cable during transportation and payoff of the wire and cable, a payoff port is coupled to the clamshell package, wherein the coiled wire and cable is extracted from the clamshell package through the payoff port on an axis substantially similar to the axis of the extracted wire and cable, and wherein the payoff port extends from the clamshell package through the coiled wire and cable.