Reel Hub Reinforcement via Post-Molding Insertion

Solution Overview

Problem

Existing methods for reinforcing reel hubs in recording tape cartridges are costly and technically challenging due to the need for dedicated equipment and complex positioning of metal reinforcement rings during insert molding, which can lead to deformation issues affecting data readability, especially in high-capacity and high-density recording tapes.

Innovation Solution

A method involving a molding process to create a resin reel configuration component with a groove for embedding a reinforcement ring, which is inserted and fixed after molding and before cooling, simplifying the process and reducing costs while effectively suppressing reel hub deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a reinforcement ring made of metal is provided to the reel hub by insert molding, then the rigidity of the reel hub is improved, but the manufacturing complexity and cost increase due to dedicated equipment and positioning requirements

Engineering Contradiction:

Improverigidity of reel hubVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The groove for receiving the reinforcement ring is formed in advance during the reel hub molding process, before the reinforcement ring is actually installed. This preliminary preparation simplifies the subsequent embedding step and eliminates the need for complex positioning mechanisms during insert molding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The reinforcement ring is extracted from the insert molding process and treated as a separate component that is embedded after the reel hub is molded. This separation removes the complexity of coordinating multiple materials and positioning requirements during a single molding operation.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If a reinforcement ring made of metal is provided to the reel hub by insert molding, then the rigidity of the reel hub is improved, but the manufacturing cost increases due to dedicated equipment requirements

Engineering Contradiction:

Improverigidity of reel hubVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The groove for receiving the reinforcement ring is formed in advance during the reel hub molding process, before the reinforcement ring is actually installed. This preliminary preparation simplifies the subsequent embedding step and eliminates the need for complex positioning mechanisms during insert molding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The reinforcement ring is extracted from the insert molding process and treated as a separate component that is embedded after the reel hub is molded. This separation removes the complexity of coordinating multiple materials and positioning requirements during a single molding operation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If the reel hub is made from resin only, then the manufacturing process is simple and cost-effective, but the reel hub deforms toward the radial direction inside when recording tape is wound tightly

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddimensional stability of reel hub

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The reel hub is constructed as a composite structure combining resin material with a metal reinforcement ring. The resin provides ease of manufacturing and corrosion resistance, while the metal ring embedded in the groove provides the necessary rigidity to prevent radial deformation when tape is wound tightly.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcement ring is strategically placed in a groove at the specific location where radial deformation occurs when tape is wound. This localized reinforcement provides dimensional stability exactly where needed, rather than requiring the entire reel hub to be made from high-strength material.

Inventive Principle:

Principle #3Local quality

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

This method allows for the simple and cost-effective provision of a reinforcement ring to the reel hub, effectively preventing radial deformation and associated data reading errors in recording tapes with high capacity and density, even when wound tightly.

Implementation Method 1

after the molding process and prior to the reel configuration component cooling and shrinking, an embedding process of embedding a reinforcement ring into the reel hub, and after the embedding process, a cooling process of cooling and shrinking the reel configuration component and fixing the reinforcement ring to the reel hub

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS10603824B2Method for manufacturing reel

Publication Date: 2020.03.31 FUJIFILM CORP

AI summary

A method for manufacturing a reel includes molding a reel configuration component that is made of resin and includes a reel hub with an outer peripheral face for winding a recording tape onto, after the molding and prior to the reel configuration component cooling and shrinking, embedding a reinforcement ring into the reel hub, and after the embedding, cooling and shrinking the reel configuration component and fixing the reinforcement ring to the reel hub.