Resin Reel Hub Radial Reinforcement via Insert Molding
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Solution Overview
Problem
Existing reel designs for winding recording tapes lack consideration for manufacturing a reinforcement insert body, leading to inadequate dimensional accuracy and protection of the recording tape.
Innovation Solution
A reel design featuring a resin-made cylindrical reel hub with an integrally extended radial flange and a metal reinforcement ring positioned internally by insert molding, which reinforces the hub and maintains dimensional accuracy of the flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal insert body is attached to a resin reel hub to reinforce rigidity, then the radial strength is improved, but the dimensional accuracy of the flange deteriorates due to manufacturing complexity
Solution Approach 1:
The metal reinforcement ring is nested inside the resin reel hub, with the reinforcement ring positioned within the cylindrical wall thickness. This nested configuration allows the metal insert to reinforce the hub radially while the resin material maintains dimensional accuracy of external features like the flange, resolving the contradiction between strength enhancement and manufacturing precision.
Solution Approach 2:
The reinforcement ring is positioned locally within the cylindrical wall of the reel hub, specifically at the inner radial side of the take-up surface, rather than uniformly throughout the entire hub. This localized reinforcement provides radial strength where needed (at the take-up surface) while leaving the flange area unreinforced to maintain its dimensional accuracy and molding quality.
2Stability of the object's composition
If a reinforcement ring is added to the reel hub structure, then the radial rigidity is improved, but the device complexity increases
Solution Approach 1:
The reinforcement ring is integrally formed with the reel hub through insert molding, combining two components (metal ring and resin hub) into a single integrated structure. This merging approach enhances radial rigidity while minimizing device complexity by creating a unified component rather than requiring separate assembly of multiple parts.
Solution Approach 2:
The reel hub employs a composite structure combining metal and resin materials, where the metal reinforcement ring provides radial rigidity and the resin material provides dimensional stability and ease of molding. This composite approach achieves enhanced mechanical properties without significantly increasing device complexity, as the two materials work together synergistically within a single molded component.
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 enhances the radial rigidity of the reel hub, prevents deformation under tape winding pressure, and ensures stable dimensional accuracy of the flange, effectively protecting the recording tape.
Implementation Method 1
a reinforcement ring that is integrally disposed at an inner radial side of a take-up surface for a taken-up object of the reel hub by insert molding, and reinforces the reel hub in the radial direction
Data Source
AI summary
The reel includes a reel hub that is made of a resin material and is formed into a cylindrical shape, an upper flange that is made of a resin material and is extended integrally outward in a radial direction from one end portion in an axial direction of the reel hub, and a reinforcement ring that is integrally disposed radially inside a tape take-up surface of the reel hub by insert molding and reinforces the reel hub in the radial direction. A position of an upper end of the reinforcement ring coincides with a position of an upper end of the tape take-up surface in the axial direction of the reel hub.