Superconducting Wire Reel With Integral Flange-and-Drum Members

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Solution Overview

Problem

Existing wire reels for superconducting wires have complex assembly processes due to individually formed components, leading to increased parts and manufacturing costs.

Innovation Solution

A wire reel design comprising a winding drum with integrally formed flange plates and drum-forming portions, allowing for easy assembly using two members and reducing the number of parts through shared molds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the winding core and side plates are individually formed and assembled, then the structural integrity and functionality are ensured, but the assembly work becomes complicated and the number of parts increases

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the winding core and side plates into a single integrally formed reel body. The reel body is formed as one piece with the winding core portion and two side plate portions extending from opposite sides, eliminating the need for separate assembly of multiple components while maintaining the structural integrity and functionality of preventing wire from coming off

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If individually formed components are used, then the functional requirements are met, but the number of dies for manufacturing increases and costs rise

Engineering Contradiction:

Improvefunctional performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The reel body is formed as a single integrated component using one mold, combining what would otherwise require separate dies for the winding core and side plates. This integral formation reduces the number of manufacturing dies needed and lowers production costs while ensuring the functional performance of wire containment

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple separate parts are assembled, then the design flexibility is maintained, but the assembly time and labor increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

By forming the reel body as a single integral piece, the patent eliminates assembly time and labor associated with joining multiple parts. The single-piece construction maintains design flexibility through the molded geometry while completely removing the assembly step, thus reducing time and labor losses

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250320083A1Wire reel

Publication Date: 2025.10.16 FARADAY FACTORY JAPAN LLC

AI summary

The present invention relates to a wire reel 1 provided with a winding drum 21 around which a superconducting wire Lis wound, a first flange plate 22 and a second flange plate 23 located at axial ends of the winding drum 21, a first member 11 integrally formed of the first flange plate 22 and a first winding drum-forming portion 24 constituting one half portion of the winding drum 21, and a second member 12 integrally formed of the second flange plate 23 and a second winding drum-forming portion 25 constituting the other half portion of the winding drum 21.