Wire Dispensing Adapter for Non-Reel Cartons
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Solution Overview
Problem
Non-reel cartons for filamentary materials lack a structural solution to be mounted on wire pulling racks, leading to issues like tangling, kinking, and structural damage, and they are not strong enough to support the weight of a full coil of wire, with hand-hole openings prone to failure, especially when wet.
Innovation Solution
An adapter with a box structure that engages with the interior of non-reel cartons, featuring a shaft-receiving sleeve and handholds, allowing the carton to be hung from a wire pulling rack without damaging the contents, distributing gravity and pulling loads over a larger surface area to prevent tearing and structural failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If non-reel cartons are mounted directly on wire pulling racks by punching a hole, then the carton can be hung for dispensing, but the carton structure is damaged and cannot support the weight of a full coil of wire
Solution Approach 1:
The patent introduces a separate mounting bracket or adapter structure that acts as an intermediary between the non-reel carton and the wire pulling rack. This bracket is attached to the carton (e.g., via straps, clips, or external mounting points) and provides the actual mounting interface to the rack, thereby enabling mounting capability without compromising the carton's structural integrity.
2Ease of operation
If the carton hand-hole opening is used for lifting and carrying, then easy handling is achieved, but the carton tears or fails, especially when wet
Solution Approach 1:
The patent separates the lifting function from the hand-hole opening by providing dedicated lifting mechanisms such as integrated handles, eyelets, or attachment points for lifting straps. This segmentation allows the hand-hole opening to remain intact for its original purpose while providing alternative, reliable means for lifting and carrying the carton.
3Productivity
If wire is pulled from a reel, then continuous dispensing is achieved, but the reel continues to spin and release extra wire that tangles or kinks
Solution Approach 1:
The patent introduces a dispensing guide or control mechanism as an intermediary between the wire and the reel/carton. This guide controls the wire's path and tension, preventing the reel from spinning uncontrollably and eliminating wire tangling while maintaining continuous dispensing capability.
4Ease of operation
If non-reel cartons are placed on the floor for dispensing, then accessibility is improved, but resistance to uncoiling causes the carton to slide in the direction of dispensing
Solution Approach 1:
The patent transitions the dispensing configuration from a floor-level horizontal arrangement to a wall-mounted or rack-mounted vertical arrangement. This dimensional change allows the carton to be positioned at ergonomic heights for better accessibility while the vertical orientation and secure mounting prevent sliding in the direction of dispensing.
Data Source
AI summary
An adapter for inserting into a carton containing a non-reel coil of filamentary material or wire has a shaft-receiving sleeve supported by a box structure. The adapter's box structure has top and back walls joined at right angles and reinforced by side walls. Knobs extend outwardly from the side walls and have openings therethrough. Ribs on the underside of the top wall define a channel which is aligned with the openings in the knobs. The ribs, top wall and knobs define a sleeve which is oriented such that it may receive a shaft or rod of a wire pulling rack. Alternatively, said adapter having a box structure with walls only in two perpendicular planes. At least two of said walls forming a channel extending outwardly that may receive a shaft or rod.