Induction Bonded Reel Hub Member Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional reel designs for winding flexible media are costly due to the use of metal T-nuts and bolts, and have limited traverse length, restricting their application to standard bolt lengths.
Innovation Solution
A reel design featuring a core and hub member bonded using susceptor material, where a magnetic field induces a bonded joint between the core and hub member, allowing for adjustable traverse length and reducing material costs by eliminating the need for metal fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal T-nuts and bolts are used to assemble the reel, then the structural integrity is maintained, but the manufacturing cost increases significantly
Solution Approach 1:
The patent merges the hub member and core into a single integrated component formed from the same plastic material, eliminating the need for separate metal fasteners (T-nuts and bolts) to assemble them. This integration maintains structural integrity while significantly reducing manufacturing cost by removing expensive metal fastening hardware and simplifying the assembly process.
Solution Approach 2:
The patent replaces expensive, durable metal fasteners with a cost-effective plastic integration approach. The hub member and core are formed as one piece from plastic material, which is cheaper than metal fastening components while providing sufficient durability for the application.
2Ease of manufacture
If standard bolt lengths are used for assembly, then the manufacturing process is simplified, but the traverse length of the reel is limited
Solution Approach 1:
By merging the hub member and core into a single integrated plastic component, the patent eliminates the constraint imposed by standard bolt lengths. The integrated design allows the traverse length to be determined by the molding process rather than by fastener length, enabling custom lengths to match specific media requirements without complicating manufacturing.
Solution Approach 2:
The patent changes the key parameter from fastener length (which is standardized) to molded component length (which is customizable). This allows the reel's traverse length to be adjusted to match any media length requirement while maintaining manufacturing simplicity through injection molding or similar processes.
3Adaptability or versatility
If dissimilar materials are used for core and flanges, then the design flexibility and functional optimization are enhanced, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the hub member and core into a single component that can be formed from the same material, simplifying manufacturing while allowing the flanges to use different materials optimized for their specific functions. This selective integration maintains design flexibility for the flanges while reducing overall manufacturing complexity.
Solution Approach 2:
The patent applies different materials to different parts of the reel based on local functional requirements. The flanges can use materials optimized for their specific functions (such as wood for stiffness or plastic for weight), while the integrated hub-member-core assembly uses a unified material suitable for its structural role, reducing overall manufacturing complexity.
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
The design simplifies manufacturing, reduces costs, and allows for reels of any desired length, maintaining structural integrity while enabling the use of dissimilar materials for the core and flanges, enhancing flexibility and cost-effectiveness.
Implementation Method 1
applying a magnetic field to the plurality of susceptor members to produce a bonded joint
Implementation Method 2
a magnetic field induces a bonded joint between the core and hub member
Data Source
AI summary
A reel includes a core having a first end region, a first flange, a first hub member, and a first bonded joint connecting the first hub member to the first end region of the core. The first bonded joint includes a first susceptor material arranged between the first hub member and the first end region of the core. The first hub member and the first end region of the core are bonded together around the first susceptor material in such a way that the first flange is interposed between the first hub member and the first end region of the core.