Spool Flange Tie-Off Feature for Stretch-Wrap-Free Media Winding
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Solution Overview
Problem
Conventional spools require the use of stretch wrap applicators and stretch wrap to retain the finish end of media, which increases complexity, cost, and reduces efficiency, and the existing tie-off holes are inconvenient and difficult to use, especially in automated processes.
Innovation Solution
A spool with a flange featuring a tie-off feature, such as a deflecting tab or flexible membrane, that allows the media to be retained without stretch wrap, simplifying the winding process and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stretch wrap applicator and stretch wrap are used to retain the finish end of media, then the media is securely retained on the spool, but the device complexity and cost increase while productivity decreases
Solution Approach 1:
The patent removes the stretch wrap applicator and stretch wrap from the winding system, extracting these components entirely. Instead, a simplified flange structure with an opening directly on the spool is used to retain the media end, eliminating the need for separate retention mechanisms and reducing overall system complexity.
Solution Approach 2:
The patent merges the media retention function directly into the spool flange structure itself. The opening in the flange serves as both a structural element and a retention mechanism, combining what were previously separate components (flange, stretch wrap, applicator) into a single integrated structure.
2Reliability
If stretch wrap applicator and stretch wrap are used to retain the finish end of media, then the media is securely retained on the spool, but the time required for winding increases reducing productivity
Solution Approach 1:
The flange opening is pre-formed as an integral part of the spool structure during manufacturing, eliminating the need for post-winding operations to apply stretch wrap. This preliminary preparation of the retention structure allows for faster winding operations without additional retention steps.
Solution Approach 2:
By removing the stretch wrap applicator and stretch wrap application steps from the winding process, the patent directly reduces the time required for winding operations, thereby increasing productivity while maintaining media retention through the simplified flange opening design.
3Reliability
If conventional tie-off holes are used on the flange, then the finish end of media can be retained, but the ease of operation deteriorates as they are inconvenient and difficult to access
Solution Approach 1:
Instead of providing discrete tie-off holes that require insertion operations, the patent inverts the approach by providing a continuous opening in the flange that allows the media end to be simply placed through and retained. This inversion of the retention mechanism significantly improves ease of operation while maintaining retention reliability.
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 spool design reduces the need for stretch wrap, minimizing complexity and cost while improving the speed and ease of use in both manual and automated winding processes.
Implementation Method 1
The transition region is defined by a deflecting tab that allows the media to pass through the transition region from the receiving portion to the retaining portion
Implementation Method 2
The transition region is defined by a flexible membrane including a pair of oppositely disposed flexing elements that allow the media to pass through the transition region
Data Source
AI summary
A spool, spooling system and associated method for winding media onto a spool includes a flange provided with a tie-off feature for retaining a finish end of the media on the spool. The spool includes a barrel and at least one flange extending outwardly from the barrel. The tie-off feature includes a receiving portion for receiving the finish end of the media and a retaining portion for retaining the finish end of the media within the tie-off feature. The tie-off feature may be in the form of a deflecting tab or a flexible membrane. The spooling system includes a feed arm for feeding the media to the spool and a drive unit for rotating the spool to wind the media onto the spool. The method includes winding the media onto the spool and retaining the finish end of the media within the tie-off feature provided on the flange.