Polygonal Wire Packaging Layout to Prevent Settling and Tangling
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Solution Overview
Problem
Conventional wire packaging methods, especially those using cylindrical containers with octagonal liners, result in wire settling during shipment, leading to increased tangling issues due to gaps between the wire and the container walls, necessitating taller containers and less efficient use of space.
Innovation Solution
A container with a polygonal liner, such as an octagonal shape, is used to package wire, where a continuous length of wire is formed into layers of polygonally arrayed loops, minimizing gaps with the container walls through controlled movement of the wire coiling apparatus in linear X-Y directions, ensuring tighter packing and reduced settling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cylindrical containers with octagonal liners are used for wire packaging, then the wire can be arranged in circular patterns, but gaps form between the wire and container walls causing wire settling during shipment
Solution Approach 1:
The patent applies asymmetry by changing from a circular wire arrangement to a polygonal wire arrangement that matches the octagonal liner geometry. The wire is formed into polygonal loops with straight sections that align with the liner walls, creating an asymmetric configuration that eliminates gaps and prevents wire settling during shipment.
2Stability of the object's composition
If taller containers are used to accommodate wire settling, then wire stability can be maintained, but container space utilization decreases
Solution Approach 1:
The patent applies preliminary action by pre-forming the wire into polygonal loops with straight sections before placement in the container. This preliminary shaping ensures that the wire maintains its configuration and prevents settling during shipment, eliminating the need for taller containers and optimizing space utilization.
3Productivity
If circular wire loops are used in octagonal containers, then wire can be packaged efficiently, but wire tangling occurs during payout operations
Solution Approach 1:
The patent applies asymmetry by using polygonal wire loops with straight sections instead of circular loops. The straight sections create a more stable, less tangled configuration that pays out smoothly during welding operations, improving reliability while maintaining packaging efficiency through the compact polygonal arrangement.
Data Source
AI summary
A container includes an outer box, and a polygonal liner located within the outer box. The polygonal liner has a plurality of vertical walls. A continuous length of wire is located within the polygonal liner and forms a plurality of layers. Each of the layers is comprised of a series of wire loops arrayed polygonally along the vertical walls of the polygonal liner.