Wire Spool Hook Slot for Electrical Isolation
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Solution Overview
Problem
Existing wire spool designs fail to effectively isolate the wire end from conductive surfaces, leading to short circuits and unnecessary wire wastage due to detachment issues during the dispensing cycle.
Innovation Solution
A spool design featuring a hook slot with a rectangular prism key and recess, along with a transition and exit pocket, that securely holds the wire end in place, preventing detachment and ensuring electrical isolation by directing the wire at a 90-degree angle and against the spool flange, thereby preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire end is constrained to a narrow position within a keyway, then electrical isolation is achieved, but the wire end becomes difficult to constrain and may detach during dispensing
Solution Approach 1:
The keyway is segmented into multiple sections: an enlarged section that receives the hook, a transition section, and a constrained section within the keyway. This segmentation allows the wire end to be securely held in the enlarged section while maintaining electrical isolation in the constrained section, resolving the contradiction between reliable isolation and ease of constraint.
Solution Approach 2:
The keyway transitions from a two-dimensional narrow slot to a three-dimensional enlarged section with vertical and horizontal dimensions. This dimensional change provides adequate space for the hook while maintaining the narrow profile needed for electrical isolation, allowing the wire end to be easily constrained without compromising isolation reliability.
2Reliability
If more wire than required is wound on the spool to prevent detachment, then wire retention is improved, but unnecessary costs result from scrapped wire
Solution Approach 1:
The enlarged keyway section automatically secures the hook and wire end without requiring additional wire length or manual intervention. The structural design itself provides the retention function, eliminating the need to add extra wire as a safety margin and preventing wire waste while maintaining reliable retention throughout dispensing.
Data Source
AI summary
A wire spool is disclosed that includes an elongate barrel that has a first end and a second end that are separated by a wall with an inner surface and an outer surface. A key is disposed on the inner surface of the barrel, wherein a recess is created within the key. A hook slot is disposed within the outer surface of the barrel, the hook slot is located above the recess and receives a start end of a wire to provide insulation thereof. The hook slot also directs a length of wire to be wound out of the hook slot for placement against a spool flange.