JP5684716B2 - Improved sewing wire spool - Google Patents

Description

  The present invention relates to a spool for winding a thin metal wire. More particularly, the present invention relates to a spool made from a sheet metal for winding a sawing wire.

  A conventional spool has a core and two flanges. The two flanges are welded to both ends of the core, for example. The core and the two flanges are 1-6 mm thick sheet metal made from carbon steel.

  An example of a small diameter metal wire to be wound on the spool is a sawing wire. The sawing wire has a diameter between 0.08 mm and 0.16 mm, most typically 0.12 mm. However, it is also known that a 0.25 mm sawing wire exists. There is a tendency to wind a sawing wire having a smaller diameter even longer. The sawing wire is used for a loose abrasive type sawing machine. In this type of sawing machine, the sawing wire serves to draw the slurry containing the liquid carrier and abrasive grains into the progressive cut of the material being sawed. This type of sawing machine is widely used to cut silicon ingots used in the semiconductor industry or solar cell manufacturing. Alternatively, the spool may be used to wind a fixed abrasive sawing wire. In this case, the abrasive is firmly attached to the wire and no carrier slurry is required.

  The spool may be used to wind a hose reinforcing wire. This type of wire is braided or spirally wound around the inner hose body to reinforce the hose. Such hoses are used, inter alia, in hydraulically operated machines. Hose wires typically have a diameter between 0.16 mm and 0.25 mm or more.

  When winding a layer of wire around a spool, each layer applied to the spool will apply pressure to the layer below it. This pressure is proportional to the force used to wind the wire around the spool and the number of layers wound. The pressure is transmitted not only to the spool core but also to the flange. This pressure causes both flanges to be pushed outward. In extreme cases, this force is too great, and the flange can disengage from the core, and in extreme cases, the core can collapse completely.

  In the sawing application described above, a single wire having a length of 800 km and a diameter of 0.12 mm is wound around the spool. As the diameter of the metal wire decreases, the cumulative number of layers of wire increases (the number of layers can increase from 500 to 800). The winding tension is typically 2 to 40 Newtons. Therefore, the side pressure generated in the flange is large. The flange will deform and expand while the wire is wound around the spool. This is extremely disadvantageous when used in a subsequent cutting process. This is because during cutting, if the pressure decreases with decreasing number of layers, the spool flange tends to return to its original position. Thus, there is an inherent risk that the remaining wire loops immediately inside the flange will be caught between the remaining wire pack and the flange and then break when pulled out of the spool.

  In order to provide sufficient strength and rigidity to withstand such side pressures, some spools according to the prior art have flanges made of metal disks having a thickness of about 20 mm to 50 mm (eg, patents). Reference 1). However, since such a spool is too heavy, its operability is extremely poor. Further, this spool has high material costs, processing costs, and transportation costs. Moreover, even with this mechanically strong spool, plastic deformation of the flange and the core cannot be avoided due to extremely high side pressure. After repeated use, the spool becomes unusable due to further deformation or breakage. Therefore, this spool cannot ensure appropriate durability compared with its high cost.

  Another solution is to attempt to make a spool having a flange with different layers of sheet metal welded together to increase the rigidity of the flange. An example of such a solution is described in Patent Document 2. However, this type of spool has a low winding capacity.

  Yet another solution is found in US Pat. Here, in order to reduce the deformation of the flange due to the side pressure of the wire winding, shot pebbing is applied to the outside of the flange.

  The most widely used spool for a sawing wire is described in Patent Document 4, but this spool is made of a thick metal sheet. This spool is sturdy but can only be used once. This is because the flange is plastically deformed after one use cycle. Furthermore, the spool is not designed to wind a wire with a diameter of 0.120 mm or less.

US Design Patent No. 399,857 European Patent No. 129536B1 Specification JP 2006-240865 A US Design Patent No. 441,772 Specification

  The object of the present invention is to eliminate the disadvantages of the prior art. A specific object of the present invention is a spool for winding a small diameter wire such as a sawing wire, which has sufficient mechanical strength to minimize the deformation of the flange and is reusable. It is to provide a spool that can be obtained. It is also an object of the present invention to achieve weight and cost reduction. Yet another object of the present invention is to make it possible to wind thinner wires having a length of 1000 km or more, for example having a diameter of 0.08 mm.

  According to an aspect of the present invention, a spool made of a thin metal plate for winding a metal wire, the spool comprising a core and two flanges connected to both ends of the core, each of the flanges A spool will be provided with a number of debossed regions extending radially outward from the core. In a preferred embodiment, the debossed areas are evenly distributed angularly around the core.

  The flange of the spool may be welded to the spool, for example. Alternatively, the flange may be brazed to the core or attached to the core by mechanical clamping means. As yet another possibility, the flange may be provided with a collar previously attached to its central hole. Here, the collar rim is welded to the core. Alternatively, the collar may be slipped into the end of the core and spot welded thereto. One skilled in the art will be able to find other ways to connect the core to the flange.

  The term “debossed area that extended radial” means that the debossed area has a longer dimension in the radial direction from the core towards the outer rim of the flange. Yes.

  For the purposes of this application, the term “debossed area” means a plastically compressed region of sheet metal. Accordingly, the debossed area is lower than the area surrounding the area. This is opposite to, for example, “embossing” for imprinting on the “head” of the coin. The embossed area is higher than the area surrounding the area.

  The dent in the debossed area can only be obtained by compression of the material. This dent in the debossed area is not obtained as a result of removing the surface material to obtain a recessed area.

  Similarly, debossing is not locally deformed by stamping a thin metal plate. During the stamping process, the thickness of the thin metal plate hardly changes, and the back of the stamped part can be seen with the naked eye from the side opposite to the stamping process side. The debossed area is hardly visible from the inside of the flange, i.e. from the mutually facing sides of the flange. The inside of the flange should be as smooth as possible so as not to cause turbulence of the wire at a position close to the inside of the flange during winding.

  It is known from material science that local compression of a material can affect the yield stress of the material. For example, the tensile yield strength of the metal strip can be increased by compressing the metal strip. Therefore, higher stress is required to yield this metal. This is known in the materials science as the “Bauschinger effect” (derived from the name of the German engineer Johann Baushinger). Without being bound by this theory, by locally debossing a flange made from sheet metal, the yield strength of the flange can be advantageously increased, thereby increasing the resistance of the wire layer to pressure. Conceivable.

  The upper limit of the surface area of a single debossed area will be limited by the tool used. That is, as the surface area increases, the depth decreases. This is because the press used is only determined to produce the maximum compression force. Regarding the lower limit, the area of the single debossed region should not be too small. This is because if it is too small, the material will flow outside the compression region, resulting in a smaller effective compression inside the region.

  In the first embodiment, the number of debossed areas is four, and preferably, the debossed areas are arranged every 90 °. In another embodiment, the number of debossed areas is 6, and preferably, the debossed areas are regularly arranged at intervals of 60 °. In still other embodiments, the number of debossed areas is between 4-18.

  The spool of the present invention has a core having an outer diameter D1 and two flanges having an outer diameter D2, and the free radius of the flange is half of (D2-D1). The spool is further characterized in that the debossed region extends radially over at least 25%, preferably at least 35%, most preferably at least 50% of the free radius. This means that the maximum dimension of the area measured in the radial direction is at least 25% of the free radius, more preferably at least 35%, most preferably at least 50%. In one embodiment, the free radius of the flange is between 5 cm and 20 cm, and the radial length of the debossed region is between 2.5 cm and 10 cm.

  The total surface area of the debossed area is greater than 2% and less than 40% of the annular surface area between the core and one rim of the flange.

  The depth of the debossed region is between 3% and 50% of the thickness of the flange. In one embodiment, the flange has a thickness of between 2.5 mm and 6.0 mm, and the depth of the debossed region is between 0.2 mm and 1.25 mm. In a particular embodiment, the flange has a thickness between 4.0 mm and 5.0 mm, and the debossed area has a depth of 0.15 mm to 2.0 mm. In a more specific embodiment, the flange has a thickness of 4.5 mm and the debossed area has a depth between 0.15 mm and 1.5 mm.

  In a preferred embodiment, the debossed region is substantially rectangular, and the long side of the rectangular shape is along the radial direction. In one embodiment, the width of the rectangular debossed region is between 5 mm and 20 mm.

  In an alternative form, the debossed area is truncated. The fan-shaped portion has a tip at the center of the flange of the spool. Each of the fan-shaped portions defines an angle when viewed from the center of the spool. The sum of the arc angles defined by the truncated sector is preferably between 10 ° and 180 °.

  In one embodiment of the invention, one or both of the flanges are provided with one or more protruding drive studs for rotating the spool during use. The drive stud is adapted to engage with a circular or semi-circular notch in the drive plate of the sawing machine. As the drive plate rotates, the spool is driven by the drive plate via the movement of the stud. The stud can be a ring and the inside of the ring will be welded to the flange. If the outside is welded, a weld burr is generated at the foot portion of the stud, and the stud cannot be properly engaged in the drive hole. Alternatively and most preferably, a disc with two mutually facing half-moon notches may be used. In this case, the welding will take place from the outside into the notch, which is much more convenient than if it must be welded in a sealed ring space.

  Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

It is a perspective view which shows the spool by this invention. 1 is a side view of a spool according to the present invention. FIG. 3 is a sectional view taken along B-B ′ of the flange of FIG. 2. It is a side view of the spool by embodiment of this invention. FIG. 6 is a side view of a spool according to certain embodiments of the invention. FIG. 6 is a side view of a spool according to certain embodiments of the invention.

  FIG. 1 shows a first embodiment of a spool 10 according to the invention. The spool 10 includes a core 12 and two flanges 14 welded to both ends of the core 12. The two flanges 14 are provided with six debossed regions 16 that are equally angularly arranged and extend radially from the core 12. The debossed region 16 is substantially rectangular. Two protruding drive studs 18 are provided for rotating the spool 10 during use. The two flanges may have a rim 20, but this is not necessarily required for the present invention.

  FIG. 2 is a side view of a first embodiment of a spool according to the present invention. The core 12 has an outer diameter D1, and the two flanges 14 have an outer diameter D2. In the first embodiment, D1 is 156 mm and D2 is 310 mm. The free radius of the flange is (D2-D1) / 2, ie 77 mm. The six debossed areas 16 have a substantially rectangular shape with a radial dimension of 40 mm. That is, about 50% of the free radius is debossed. The width of the debossed area is about 8 mm. About 3% of the free area is debossed.

  3 is a cross-sectional view of the flange of FIG. 2 along B-B ′. This figure shows that the flange 14 has a thickness 'd' and the debossed region 16 has a thickness 'δ'. 'Δ' is between 50% and 97% of the thickness 'd' of the flange 14, which means that the steel sheet is compressed from 3% to 50%. In the first embodiment, the thickness “d” of the metal thin plate is 4.5 mm, and the thickness “δ” of the recessed region is 4.0 mm, whereby the debossed region has a depth of 0.5 mm. Will have. In practice, it is easier to measure both thicknesses ‘d’ and ‘δ’ and then derive the depth of the debossed region than to directly measure the depth of the recessed region.

  Debossing is performed by, for example, pressing a pressing die made of hardened steel having a desired region shape into a flange separate from the flange by an impact press. This is done at room temperature and no other treatment is required. The important thing is that the impression of the embossing does not appear very large inside the flange, i.e. there should be no protrusions on the inside of the flange, even if a slight trace is visible. is there. Such a protrusion will impair the winding quality of the thin metal wire.

  FIG. 3 also shows how the flange 14 is attached to the core 12 via two welded seams 15, 17 on each of the inside and outside of the flange. The stud 18 is made of a ring having a diameter of 27 mm and a height of 12 mm, which is welded to the flange 14 from the inside.

  FIG. 4 is a side view of a spool according to an alternative embodiment of the present invention that differs from the first embodiment only in that the protruding drive stud 18 has a different shape. These studs are made from a solid disk having a diameter of 27 mm and a height of 12 mm from which two meniscus parts have been cut off. In this case, the welding of the stud to the flange is very easy. This is because the stud can be welded from the outside to the cut portion. FIGS. 5 and 6 illustrate another preferred embodiment of the present invention in which the total surface area of the debossed region 16 is greater than the surface area of the six debossed regions 16 shown in the previous figure.

  FIG. 5 shows a flange having six debossed regions 16 in the form of a truncated fan. The arc angle ‘α’ of one debossed region 16 is about 30 °. The total arc angle defined by the truncated sector is about 180 °. About 23% of the annular surface area between the core and rim is debossed.

  FIG. 6 shows a particular embodiment of the invention in which each of the two flanges comprises 18 debossed areas 16.

  A test was performed comparing the spool of the present invention with a conventional spool which differs only in that there is no debossed area on the flange. The dimensions of the spool and the debossed area are those described in the first embodiment.

  A conventional spool and a spool of the present invention were tested as follows. That is, a 0.14 mm diameter thin wire was wound around each spool with a controlled winding tension of about 3.5 Newtons and a winding step of 0.15 mm. These are more severe conditions than usual. The winding was stopped at the respective thin wire lengths of 200 km, 400 km and 800 km. When stopped, the inner flange width was accurately measured in the axial direction with an insert gauge at the spool rim (diameter D2). The deformation is greatest at the rim of the spool. The results shown in Table 1 show that there is less deformation at both ends of the flange in the spool of the present invention compared to the conventional spool. A spool wound with a thin wire having a diameter of 200 km shows that the spool does not deform at all as compared with a conventional spool that exhibits a deformation of 0.2 mm. A spool wound with 400 km of a thin wire shows a 2/3 deformation of the conventional spool. A spool wound with 800 km of thin wire is still somewhat less deformed, showing improvements. Thus, these results infer that further improvements can be obtained by extending the debossed region over a longer radial length.

  Finally, considerable improvements have been obtained when compared to flange deformation in prior art spools such as described, for example, in US Design Patent No. 441,772. Indeed, spools according to the prior art show flange spreads of more than 10 mm under the same test conditions as in the tests made for conventional and inventive spools.

Claims (12)

A spool (10) made of sheet metal for winding a metal wire having a diameter of 0.08Mm～0.16Mm, core (12) and two flanges which are connected to both ends of the core (12) (14) In the spool (10), the outer side of each of the flanges (14) is a plurality of debossed regions (16) plastically compressed at room temperature on a thin metal plate, and is radially from the core (12). extends while provided with a debossed area (16), the inside of the flange is adapted to Tan Taira, said debossed areas (16) are angularly around the core (12) are evenly distributed, the number of the debossed regions (16), der between 4 and 18 is, the depth of the debossed regions is 50% to 3% of the thickness ( 'd') of the flange (14) vinegar and wherein between near Rukoto of Lumpur.   The core (12) has an outer diameter D1, and the two flanges (14) have an outer diameter D2, whereby the free radius of the flange (14) is (D2- D1) and the debossed region (16) extends radially over at least 25%, preferably at least 35%, most preferably at least 50% of the free radius. The spool according to claim 1, wherein:   3. The free radius of the flange (14) is between 5 cm and 20 cm, and the radial length of the debossed region (16) is between 2.5 cm and 10 cm. Spool described in.   The total surface area of the debossed region (16) is greater than 2% and less than 40% of the annular surface area between the core (12) and one rim (20) of the flange (14). The spool according to any one of claims 1 to 3, wherein the spool is provided. The flange (14) has a thickness between 2.5 mm and 6.0 mm, and the depth of the debossed region (16) is between 0.2 mm and 1.25 mm. The spool according to claim 1 . The flange (14) has a thickness between 4.0 mm and 5.0 mm, and the debossed region (16) has a depth between 0.15 mm and 2.0 mm. It characterized that you have to spool according to claim 1. The flange (14) has a thickness of 4.5 mm , and the debossed region (16) has a depth between 0.15 mm and 1.5 mm, The spool according to claim 1 . The DeVos region (16), the spool according to any of claims 1 to 7, essentially characterized in rectangular der Rukoto. 9. Spool according to claim 8 , characterized in that the width of the rectangular debossed area (16) is between 5 mm and 20 mm . The spool according to any one of claims 1 to 7, wherein the debossed region (16) has a truncated fan shape . 11. A spool according to claim 10 , characterized in that the sum of the arc angles defined by the fringe fan is between 10 [deg.] And 180 [deg .]. On one or both of the flange (14), wherein the one or more protruding drive studs for rotating take spool (10) (18) is characterized that you have provided during use, The spool according to any one of claims 1 to 11 .

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