Thermoplastic Spool Assembly With Welded Core-Flange Joint
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Solution Overview
Problem
Existing spools with hollow cores face issues with connections between annular flanges and core that are prone to failure under increased loads, and require elaborate manufacturing methods, especially with soldering which is prone to flaws and additional material requirements.
Innovation Solution
A spool design using three individual parts with a tubular spool core and flange discs, where the core is connected to the flange discs via a materially bonded method like welding, eliminating the need for additional connection materials and allowing for modular dimensions and easy recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soldering is used to connect the spool core to the flange discs, then a materially bonded connection is formed, but the connection is prone to failure, flaws, and requires additional soldering material and effort
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical pressing connection system. The spool core is pressed into the annular recess of the flange discs, creating a mechanically bonded connection without requiring soldering material or thermal processing. This eliminates the reliability issues associated with soldering flaws while maintaining strong connection strength through precise mechanical interference fit.
Solution Approach 2:
The invention extracts and eliminates the soldering material from the connection process. By designing a press-fit mechanism where the spool core directly engages with the annular recess, the patent removes the need for additional soldering materials and the complex soldering process entirely, simplifying both the connection method and material requirements.
2Strength
If soldering is used to connect the spool components, then a materially bonded connection is achieved, but additional soldering material and local application effort are required
Solution Approach 1:
The patent substitutes the complex soldering process with a simple mechanical pressing operation. The spool core is pressed into the annular recess using pressing equipment, eliminating the need for soldering material application, heating equipment, and skilled soldering operations. This dramatically improves ease of manufacture while maintaining connection strength.
Solution Approach 2:
The invention removes the additional soldering material requirement entirely by designing a direct mechanical connection. The spool core itself serves as the connecting element through its press-fit engagement with the annular recess, eliminating the need for separate connection materials and reducing manufacturing steps.
3Adaptability or versatility
If the spool is designed with a hollow core and flange discs, then winding material can be transported, but the connections between flanges and core cannot withstand increased loads
Solution Approach 1:
The patent utilizes the curved annular shape of the recess and the corresponding annular geometry of the spool core to distribute loads evenly around the connection interface. This curved geometric design allows the connection to withstand increased radial and axial loads while maintaining the hollow core structure necessary for winding material transport.
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 solution provides a strong, stable connection without additional materials, enabling easy manufacturing and recycling, and allows for diverse spool dimensions and increased bending strength, while avoiding the flaws associated with soldering.
Implementation Method 1
heating the material in the contact area between the spool core and the annular wall to a melting point as the molten material flows into the at least one channel
Implementation Method 2
heating the material in the contact area between the spool core and the annular wall to a melting point as the molten material flows into the at least one channel
Data Source
AI summary
A spool for winding strand-shaped material having flange discs (22, 24) with an outer flange surface and an inner flange surface (21, 23) as well as a method for manufacturing the spool. The discs have a central through bore (30) that is surrounded by an annular recess (25) with an annular wall (26) positioned in the inner flange surface. A tubular spool core (10) has front surfaces which are connected in a materially bonded manner to the annular wall (26) inside the annular recess (25) of the flange discs (22, 24), wherein at least one channel (32) is provided next to the annular wall (26) inside the annular recess (25) for receiving liquefied connection material. The spool core (10) has approximately the same diameter as the annular wall (26) inside the annular recess (25).