Stackable Wire Dispensing Container with Segmented Core
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Solution Overview
Problem
Existing wire and cable dispensing containers, such as wooden reels and barrel packs, are cumbersome, prone to damage, and require significant effort to dispense wire due to their weight and design, leading to tangling and snags, and lack convenience in transportation and stacking.
Innovation Solution
A stackable wire dispensing container with a corrugated cardboard enclosure, a core, and support elements, featuring precut payoff holes and handles, allowing wire dispensing without rotating the entire coil, enabling easy transportation and stacking, and accommodating various materials without compromising functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wooden reels or metal spools are used to wind and dispense wire, then the wire can be stored and dispensed, but the reels become heavy, cumbersome, and difficult to carry due to lack of handles and absorb water in wet conditions
Solution Approach 1:
The reel is divided into a hub and separate spokes that can be assembled, allowing for lighter materials and easier handling. The segmented design reduces overall weight while maintaining structural integrity for wire storage and dispensing.
Solution Approach 2:
A handle is introduced as an intermediary component between the user and the reel, providing leverage and ease of transportation without requiring the entire reel to be carried directly. This mediator element solves the cumbersome handling problem.
2Reliability
If traditional reels and spools are used, then wire can be stored, but they are prone to damage such as splintering or shattering if dropped
Solution Approach 1:
The reel is constructed from composite materials that combine the strength needed to hold wire with damage resistance. The hub and spokes use materials that resist splintering and shattering while maintaining the necessary structural integrity for wire storage and dispensing operations.
3Ease of operation
If traditional reels require jack stands and shafts to support during pay-off, then the reel can be supported, but additional equipment must be transported and used
Solution Approach 1:
The support function previously requiring separate jack stands and shafts is merged into the reel structure itself. The reel's hub and spoke design provides inherent support capabilities, eliminating the need for additional external equipment while maintaining proper pay-off support.
Solution Approach 2:
The reel is designed to perform multiple functions: storing wire, providing structural support during pay-off, and enabling easy transportation. This multi-functionality eliminates the need for separate specialized equipment like jack stands and shafts.
4Ease of operation
If traditional reels require additional pulling force to rotate the entire weight during payoff, then wire can be dispensed, but significant force is needed
Solution Approach 1:
The segmented hub and spoke design reduces the effective rotating mass during pay-off. By dividing the reel structure, less force is required to rotate the components during wire dispensing while maintaining the ability to store and support the wire.
5Productivity
If traditional reels allow rotation during payoff, then wire can be dispensed, but inertia causes overruns that increase risk of tangles and snags
Solution Approach 1:
The reel's dynamic response during pay-off is optimized through the hub and spoke design, allowing controlled rotation that prevents excessive inertia-driven overruns. This dynamic control maintains wire dispensing efficiency while reducing tangle and snag risks.
Data Source
AI summary
An apparatus for dispensing wire or cable, the apparatus including an enclosure with a top and a bottom portion and at least three side portions of a first height, a plurality of holes located in both the top and bottom portions of the enclosure, and a core of a second height located within the enclosure, wherein the core forms an area, wherein at least one of the plurality of holes has a first hole diameter and is located in the top and bottom of the enclosure and is located within the area formed by the core, and wherein the wire or cable is placed around the core.