Single-Reel Layering of Multiple Conduit Runs for Distortion-Free Payout

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Solution Overview

Problem

The installation of multiple conduit runs requires multiple reels or segmented reels, which is time-consuming and expensive, and segmented reels can cause conduit distortion due to their diameter.

Innovation Solution

Layering multiple conduit runs onto a single reel, with each run wound in layers and covered by protective layers, allowing separate payout at the jobsite.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple reels or segmented reels are used to hold and transport multiple conduit runs, then each conduit run can be transported separately, but the loading process becomes time-consuming and expensive

Engineering Contradiction:

Improveloading speedVSAvoidnumber of reels

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple conduit runs onto a single reel by layering them in a stacked configuration. The first conduit run is wound on the reel drum, the second conduit run is wound over the first, and so on. This merging approach allows multiple conduit runs to be transported on one reel instead of requiring multiple separate reels or segmented reels, thereby reducing loading time and costs while maintaining the ability to transport and install multiple conduit runs separately at the jobsite.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If segmented reels with drums are used to transport multiple conduit runs, then multiple conduit runs can be transported, but the drum diameter causes distortion to the conduit

Engineering Contradiction:

Improvetransport capabilityVSAvoidconduit shape

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent resolves the distortion issue by changing the spatial arrangement from a radial configuration (conduits wrapped around a drum circumference) to a stacked layered configuration. Multiple conduit runs are wound onto the reel in successive layers, with each layer stacked over the previous one. This dimensional change allows the conduit to be wound in a manner that prevents distortion while still enabling multiple conduit runs to be transported on a single reel.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If multiple reels are used to transport multiple conduit runs, then separate transport is possible, but the cost increases

Engineering Contradiction:

Improvetransport flexibilityVSAvoidnumber of reels required

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent merges multiple conduit runs onto a single reel, reducing the number of reels required from multiple to one. This is achieved by winding the first conduit run on the reel drum and then winding subsequent conduit runs over the first run in layered stacks. This merging maintains transport flexibility and the ability to install conduit runs separately, while significantly reducing the quantity of reels needed and associated costs.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250333260A1Systems and Methods for Layering Multiple Conduit Runs Onto a Reel

Publication Date: 2025.10.30 SOUTHWIRE CO LLC

AI summary

Systems and methods for layering multiple runs of conduit on a single reel are provided. According to embodiments, a reel includes a first conduit run wound onto the reel in a first layer. The first conduit run includes at least one conduit. One or more sheets of material can be wound onto the reel in a first protective layer over at least a portion of the first conduit run. The reel can also include a second conduit run comprising at least one conduit. The second conduit run can be wound onto the reel in a second layer over the first layer of the first conduit run and the first protective layer.