200944462 九、發明說明 【發明所屬之技術領域】 本發明有關一捲線筒，一細微金屬線係纏繞在該捲線 筒上。更特別地是，本發明有關一由厚金屬板所製成之捲 線筒’用於一細微金屬線、諸如用於線鋸之金屬線（下文 ' 稱爲“鋸條”）或一強化橡膠軟管之金屬線（下文稱爲“ 軟管金屬線”），以纏繞在其上面。 ❿ 【先前技術】 如圖1所示之傳統捲線筒1 0具有一核心1 2及二凸緣 14。該二凸緣14被焊接至核心12之兩端部。該核心12 及該二凸緣14係由厚金屬板所製成，諸如用於機器結構 之使用的碳鋼。 待纏繞在該前述捲線筒上之細微金屬線係譬如一具有 0」2至0.16毫米或更少之直徑及具有鋸條之作用的細微 Ο 金屬線，或一具有大約0.20至0.80毫米直徑及具有軟管 金屬線之作用的細微金屬線。另一應用係一具有大約0.12 至0.40毫米之直徑、及具有用於絞合鋼絲簾線以強化橡 膠產品的金屬線之作用的細微金屬線。 於該前述細微金屬線係在一預定張力（譬如，4至15 牛頓之張力）之下纏繞在該捲線筒上之案例中，該纏繞張 力對該核心造成一高繫緊張力’如此導致對該等凸緣施加 一大力量而推開它們。且此用於推開之力量（下文稱爲“ 側面壓力”）在兩端造成該等凸緣於一將它們彼此分開之 -5- 200944462 方向中被推開。 於一典型之應用中，一鋸條被用於切割用於微晶片之 矽。爲消除材料之浪費及維持一高生產力，該等顧客正要 求以一細微金屬線纏繞之捲線筒，該金屬線具有0.12毫 米之直徑及800公里之長度。當該金屬線之直徑變得較小 時，或當該纏繞張力變得較大時，或當該金屬線之往復圈 數變得較大時，所產生之側面壓力變得較大。 爲提供充分之強度及剛性以耐受住此側面壓力，該傳 ❹ 統捲線筒10利用具有大約20毫米至50毫米的厚度之厚 金屬板。據此，該傳統捲線筒係如此重，以致其操作性變 得很不佳，且該捲線筒遭受高運送成本。該傳統捲線筒亦 遭受高的材料及處理成本。 此外，既然該側面壓力係過大，甚至此機械式強固之 捲線筒不能避免該等凸緣及該圓筒之塑性變形。在幾次的 重複使用之後，該捲線筒之變形正持續進行，或該捲線筒 被打破至變得不堪用。亦即，該傳統捲線筒具有一缺點， © 即其無法確保對於該高成本爲適當的耐用性。 因此，本發明的一目標係提供一用於超細微金屬線之 捲線筒，而具有充分之機械強度及重複的可用性，同時達 成重量及成本中之減少，及提供一製造該捲線筒之方法。 【發明內容】 本發明有關一由厚金屬板所製成之捲線筒，用於一細 微金屬線。該捲線筒包括一核心及耦接至該圓筒之二凸緣 -6- 200944462 。該核心另包括二同心圓筒：即一具有內徑d之內部圓筒 、與一具有外徑D之外部圓筒。本發明改變側面壓力的負 載分布，且進一步改善該捲線筒頂抗變形之結構剛性。 【實施方式】 於圖1中，以橫截面視圖顯示一傳統之捲線筒。該捲 線筒10具有一核心12及耦接至該核心12之二凸緣14。 〇 於圖2中，在此以一倂入本發明之捲線筒的橫截面視 圖顯示。該捲線筒20具有一核心22及耦接至該核心22 之二凸緣24，而該核心22包括二同心圓筒、一具有內徑 d之內部圓筒26、及一具有外徑D之外部圓筒28。 如在圖3中所示，該等凸緣14係在由細微金屬線之 張力所產生的側面壓力F2之下。一部份該凸緣14上之負 載分布能被簡化爲以均勻分佈的側面壓力F2支撐在一端 部之樑。而如圖4中所示，該等凸緣24係在由細微金屬 © 線之張力所產生的側面壓力F4之下。一部份該凸緣24上 之負載分布能被簡化爲以均勻分佈的側面壓力F4支撐在 一端部及當中之樑。此雙支撐樑之結構係比被支撐在一端 部之樑較強。 此外，我們發現： 1 .更多層纏繞在該核心上之細微金屬線，則該核心 上之壓力越高，因爲更多金屬線施加張力在該核心上； 2.更多層纏繞在該核心上之細微金屬線，則該等凸 緣上之側面壓力越高，因爲更多金屬線施加張力在該等凸 -7- 200944462 緣上。 因此，增加該外部圓筒之外徑D有助於減少纏繞在該 圓筒上之細微金屬線層，且進一步有助於減少該核心上之 壓力及該等凸緣上之側面壓力。另外’當0及D係增加 時，該捲線筒於該纏繞及退繞製程期間之轉速減少，這將 使得該金屬線靠近該等凸緣之定位更受控制’且如此較無 問題。但在此對於該外部圓筒之外徑及該凸緣的外徑之擴 展總是有一限制，因爲該捲線筒將裝入該鋸床上之空間。 @ 因此，該外徑D係於該內徑d的1.3及2.1倍之間，而該 凸緣之外徑Φ係於該內徑d的2.2及2.8倍之間。 進一步改良係延伸該捲線筒之高度Η，以進一步減少 該圓筒上之細微金屬線的料層。既然該捲線筒將裝入該鋸 床上之空間，對於該捲線筒之高度Η的延伸有一限制。因 此，該捲線筒之高度Η、亦即該外部圓筒之高度Η係於該 內徑d的2.0及3.0倍之間。 以下於傳統捲線筒、即捲線筒〇及倂入本發明之諸捲 〇 線筒、即捲線筒1及捲線筒2的比較可進一步說明該等改 良及利益。如圖1所示，一傳統捲線筒具有以下之規格： d=l 50毫米； φ =3 1 5毫米； H = 3 1 5毫米； 而如圖2所示’倂入本發明之捲線筒具有以下之規格 -8 - 200944462 d D Φ Η 捲線同1 150毫米 230毫米 355毫米 326毫米 捲線筒2 150毫米 300毫米 400毫米 420毫米 如果該等捲線筒、即捲線筒〇之傳統捲線筒及倂入本 發明之捲線筒1&捲線筒2之二捲線筒，係纏繞相同體積 之細微金屬線，與傳統捲線筒之那些比較，該核心上之壓 力、及倂入本發明之捲線筒的凸緣上之側面壓力係急劇地 減少，而該結構剛性急劇地增加。 以該核心及凸緣上之負載分布上之改良、及該捲線筒 的結構剛性上之改良，與傳統捲線筒相比較，本發明能使 用具有於2.5毫米及7.0毫米之間，且較佳地是於3.0毫 米及5.0毫米間之厚度的較薄金屬板，以製成捲線筒。 以下表格說明倂入本發明之捲線筒的改良及利益。 強度：在一次完整 纏繞之後，凸緣間 之距離 重複的可用性 在一次使用之後，無金 屬線的凸緣間之距離 在5次使用之後，無金 屬線的凸緣間之距離 捲線筒〇 323.6毫米 318.3毫米 324.1毫米 捲線筒1 328.0毫米 326.5毫米 328.0毫米 捲線筒2 422.0毫米 420.5毫米 422.0毫米 上面之比較測試進一步揭示該比率 Φ /D對於此雙圓 筒捲線筒係亦重要的。該比率 Φ /D越小，則該捲線筒在 使用之後的變形越小，且因此重複使用該捲線筒更多次。 但在此對於比率 φ /D應有一些限制。一方面，用於比率 -9- 200944462 0/D之下限應爲大於1.0，因爲該凸緣之外徑Φ應是比該 外部圓筒之外徑D較大的，以造成該捲線筒可運轉的。在 另一方面，用於比率φ/D之上限應爲僅只2.0，因爲該凸 緣超過該外部圓筒越高，則該捲線筒在使用之後的變形越 大。因此，該比率Φ /D係於1 . 〇及2.0之間，且更較佳地 是於1.3及1.6之間。 如在圖5中所示，該凸緣24具有一中心孔洞30及環 繞著該中心孔洞之均勻分佈凹槽32。如圖6所示，該內部 q 圓筒26之外周邊及該等凸緣24上之中心孔洞30的內周 邊之間有一焊接。如在圖7所示，該外部圓筒28之內周 邊及該等凸緣24上的均勻分佈凹槽32之間有一焊接。該 上面之配置具有以下優點： 1. 改良該內部圓筒及該等凸緣間之連接； 2. 改良該外部圓筒及該等凸緣間之連接； 3. 保證該內部圓筒及該外部圓筒間之同心；BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bobbin in which a fine metal wire is wound around a bobbin. More particularly, the invention relates to a spool made of thick metal sheets for a fine metal wire, such as a wire for a wire saw (hereinafter referred to as a "saw blade") or a reinforced rubber hose A metal wire (hereinafter referred to as "hose wire") is wound around it. ❿ [Prior Art] The conventional spool 10 shown in Fig. 1 has a core 1 2 and two flanges 14. The two flanges 14 are welded to both ends of the core 12. The core 12 and the two flanges 14 are made of thick metal sheets, such as carbon steel for use in machine construction. The fine metal wire to be wound around the aforementioned bobbin is, for example, a fine ruthenium wire having a diameter of 0"2 to 0.16 mm or less and having a saw blade function, or a diameter of about 0.20 to 0.80 mm and having a soft A thin metal wire that acts as a tube metal wire. Another application is a fine metal wire having a diameter of about 0.12 to 0.40 mm and having a function of stranding a steel cord to strengthen a metal wire of a rubber product. In the case where the aforementioned fine metal wire is wound on the spool under a predetermined tension (for example, a tension of 4 to 15 Newtons), the winding tension causes a high tension to the core. The flanges apply a large force and push them away. And this force for pushing open (hereinafter referred to as "side pressure") causes the flanges to be pushed apart at both ends in a direction that separates them from each other -5-200944462. In a typical application, a saw blade is used to cut the crucible for the microchip. In order to eliminate material waste and maintain a high level of productivity, these customers are demanding a spool wound with a fine metal wire having a diameter of 0.12 mm and a length of 800 km. When the diameter of the metal wire becomes smaller, or when the winding tension becomes larger, or when the number of reciprocating turns of the metal wire becomes larger, the generated side pressure becomes larger. In order to provide sufficient strength and rigidity to withstand this side pressure, the transfer spool 10 utilizes a thick metal plate having a thickness of about 20 mm to 50 mm. According to this, the conventional reel is so heavy that its operability becomes poor, and the reel suffers from high shipping cost. This conventional reel also suffers from high material and processing costs. Moreover, since the side pressure is too large, even the mechanically strong reel cannot avoid plastic deformation of the flange and the cylinder. After several repeated uses, the deformation of the spool is continuing, or the spool is broken to become unusable. That is, the conventional spool has a drawback, that is, it cannot ensure proper durability for the high cost. Accordingly, it is an object of the present invention to provide a spool for ultrafine metal wires with sufficient mechanical strength and repeatability while achieving a reduction in weight and cost, and a method of making the spool. SUMMARY OF THE INVENTION The present invention is directed to a spool made of a thick metal plate for use in a fine metal wire. The spool includes a core and two flanges -6-200944462 coupled to the cylinder. The core further comprises two concentric cylinders: an inner cylinder having an inner diameter d and an outer cylinder having an outer diameter D. The present invention changes the load distribution of the side pressure and further improves the structural rigidity of the spool top against deformation. [Embodiment] In Fig. 1, a conventional spool is shown in a cross-sectional view. The spool 10 has a core 12 and two flanges 14 coupled to the core 12. In Fig. 2, a cross-sectional view of the spool of the present invention is shown here. The spool 20 has a core 22 and two flanges 24 coupled to the core 22, and the core 22 includes two concentric cylinders, an inner cylinder 26 having an inner diameter d, and an outer portion having an outer diameter D. Cylinder 28. As shown in Figure 3, the flanges 14 are below the side pressure F2 resulting from the tension of the fine metal wires. The load distribution on a portion of the flange 14 can be simplified to support the beam at one end with a uniformly distributed side pressure F2. As shown in Figure 4, the flanges 24 are below the side pressure F4 produced by the tension of the fine metal © wire. The load distribution on a portion of the flange 24 can be simplified to support the beam at one end and in the middle with a uniformly distributed side pressure F4. The structure of the double support beam is stronger than the beam supported at one end. In addition, we found that: 1. More layers of fine metal wires wound on the core, the higher the pressure on the core, because more metal wires exert tension on the core; 2. More layers are wound around the core On the fine metal wires, the side pressure on the flanges is higher because more metal wires exert tension on the edges of the convex -7-200944462. Therefore, increasing the outer diameter D of the outer cylinder helps to reduce the layer of fine metal wires wound on the cylinder and further helps to reduce the pressure on the core and the side pressure on the flanges. In addition, as the 0 and D lines increase, the rotational speed of the spool during the winding and unwinding process is reduced, which will make the positioning of the wire closer to the flanges more controlled' and thus less problematic. However, there is always a limit to the extension of the outer diameter of the outer cylinder and the outer diameter of the flange, since the spool will fit into the space on the sawing bed. Therefore, the outer diameter D is between 1.3 and 2.1 times the inner diameter d, and the outer diameter Φ of the flange is between 2.2 and 2.8 times the inner diameter d. A further improvement extends the height Η of the spool to further reduce the layer of fine metal wires on the cylinder. Since the spool is to be loaded into the space on the saw, there is a limit to the height of the spool. Therefore, the height Η of the spool, that is, the height of the outer cylinder, is between 2.0 and 3.0 times the inner diameter d. These improvements and benefits are further illustrated by comparison of conventional spools, i.e., reel spools, and spools of the present invention, i.e., spool 1 and spool 2. As shown in Fig. 1, a conventional reel has the following specifications: d = l 50 mm; φ = 3 15 mm; H = 3 15 mm; and as shown in Fig. 2, the reel of the present invention has The following specifications -8 - 200944462 d D Φ Η Winding line with 1 150 mm 230 mm 355 mm 326 mm reel 2 150 mm 300 mm 400 mm 420 mm If these reels, ie reel, traditional reel and intrusion The two bobbins of the reel 1& reel 2 of the present invention are wound with the same volume of fine metal wires, compared with those of the conventional reel, the pressure on the core, and the flange of the reel of the present invention. The side pressure is drastically reduced, and the rigidity of the structure is drastically increased. With improvements in the load distribution on the core and flange, and improvements in the structural rigidity of the spool, the present invention can be used between 2.5 mm and 7.0 mm, and preferably with a conventional spool. A thinner metal plate having a thickness of between 3.0 mm and 5.0 mm to form a reel. The following table illustrates the improvements and benefits of the reel of the present invention. Strength: After a complete winding, the availability of the distance between the flanges is repeated. After one use, the distance between the flanges of the metal-free wire is after 5 uses, and the distance between the flanges without the wire is 303.6 mm. 318.3 mm 324.1 mm reel 1 328.0 mm 326.5 mm 328.0 mm reel 2 422.0 mm 420.5 mm 422.0 mm The above comparison test further reveals that this ratio Φ / D is also important for this dual cylinder reel system. The smaller the ratio Φ /D, the smaller the deformation of the spool after use, and thus the spool is reused more times. However, there should be some restrictions on the ratio φ /D. On the one hand, the lower limit for the ratio -9-200944462 0/D should be greater than 1.0, since the outer diameter Φ of the flange should be larger than the outer diameter D of the outer cylinder to cause the spool to operate. of. On the other hand, the upper limit for the ratio φ/D should be only 2.0, since the higher the flange than the outer cylinder, the greater the deformation of the spool after use. Therefore, the ratio Φ / D is between 1. 〇 and 2.0, and more preferably between 1.3 and 1.6. As shown in Figure 5, the flange 24 has a central bore 30 and a uniformly distributed recess 32 that surrounds the central bore. As shown in Figure 6, there is a weld between the outer periphery of the inner q-cylinder 26 and the inner periphery of the central bore 30 in the flanges 24. As shown in Figure 7, there is a weld between the inner circumference of the outer cylinder 28 and the evenly distributed grooves 32 on the flanges 24. The above configuration has the following advantages: 1. improving the connection between the inner cylinder and the flanges; 2. improving the connection between the outer cylinder and the flanges; 3. securing the inner cylinder and the outer portion Concentric between cylinders;
4. 因爲該外部圓筒及該等凸緣間之有限制的焊接而 U 限制凸緣之變形； 5. 因爲該簡化之結構而易於製造； 如在圖8所示’於該外部圓筒28之外周邊及該等凸 緣24的表面之間有一焊接。此焊接進一步改良該外部圓 筒及該等凸緣間之連接，且改良該捲線筒之結構剛性。 製造一倂入本發明的捲線筒之方法包括ζ 1.該凸緣24係藉由該厚金屬板之壓製加工所製成’ 且該凸緣24之外周邊係大致上藉由一折疊程序所強化。 -10- 200944462 該中心孔洞30及該等均勻分佈凹槽32被該壓製加工所製 成。 2. 該內部圓筒26及該外部圓筒28係藉由將金屬板 彎曲成一圓柱形狀所形成。 3. 該內部圓筒26之外周邊被焊接至該等凸緣24上 之中心孔洞3 0的內周邊； 4. 該外部圓筒28之內周邊被焊接至該凸緣24上之 〇 均勻分佈凹槽32; 5. 該外部圓筒28之外周邊被焊接至該凸緣24之表 面。 . 6. 該內部圓筒26之兩端部可具有一倒角’以有利於 該捲線筒安裝在該等機器上； 7. 該外部圓筒28之外周邊及該等凸緣24的表面間 之焊接可被切割及製成圓形’以有利於平順之纏繞及重繞 製程。 © 對本發明之另一改良係在該內部圓筒26之外周邊及 該外部圓筒28的內周邊之間焊接一些支撐板34，如在圖 9所示。該等支撐板34改良外部圓筒28頂抗變形之強度 ，且確定該內部圓筒26及外部圓筒28係同心的。 對本發明之進一步改良係環繞著該等凸緣24上之中 心孔洞30製成該倒角，如在圖10所示，且將該外部圓筒 28之端部焊接至該等凸緣24之表面。因此，其不需要於 該內部圓筒26之端部及該等凸緣24的表面之間焊接，因 爲當該捲線筒係載入細微金屬線時，該內部圓筒28之端 -11 - 200944462 部係在一頂抗該等凸緣24之表面的壓力之下。 【圖式簡單說明】 本發明現在將參考所附圖面被更詳細地敘述，其中 圖1係一傳統捲線筒之橫截面視圖； 圖2係一倂入本發明之捲線筒的A- A橫截面視圖； 圖3係一槪要圖，顯示具有傳統捲線筒的凸緣上之側 面壓力的負載分布； © 圖4係一槪要圖，顯示具有倂入本發明之捲線筒的凸 緣上之側面壓力的負載分布； 圖5係一倂入本發明之捲線筒的側視圖； 圖6係該內部圓筒之外周邊及該等凸緣上之中心孔洞 的內周邊間之焊接的詳細圖示； 圖7係該外部圓筒之內周邊及該等凸緣上的均勻分佈 凹槽間之焊接的詳細圖示； 圖8係該外部圓筒之外周邊及該等凸緣的表面間之焊 © 接的詳細圖不； 圖9係一倂入本發明之具有支撐裝置的捲線筒之橫截 面視圖； 圖10係環繞該中心孔洞的倒角之詳細圖示。 【主要元件符號說明】 10 :捲線筒 1 2 :核心 -12- 200944462 1 4 :凸緣 20 :捲線筒 22 :核心 24 :凸緣 2 6 :內部圓筒 ' 28 :外部圓筒 3 0 :中心孔洞 〇 32:均句分佈凹槽 3 4 :支撐板 d :內徑 D :外徑 Φ :外徑 Η :高度 F2 :側面壓力 F 4 :側面壓力4. U limits the deformation of the flange due to the limited welding between the outer cylinder and the flanges; 5. is easy to manufacture because of the simplified structure; as shown in Fig. 8 'to the outer cylinder 28 There is a weld between the outer periphery and the surface of the flanges 24. This welding further improves the connection between the outer cylinder and the flanges and improves the structural rigidity of the spool. A method of manufacturing a spool of the present invention includes: 1. The flange 24 is formed by press working of the thick metal plate and the outer periphery of the flange 24 is substantially by a folding process strengthen. -10-200944462 The central hole 30 and the uniformly distributed grooves 32 are formed by the press working. 2. The inner cylinder 26 and the outer cylinder 28 are formed by bending a metal plate into a cylindrical shape. 3. The outer periphery of the inner cylinder 26 is welded to the inner periphery of the central bore 30 on the flanges 24. 4. The inner periphery of the outer cylinder 28 is evenly distributed after being welded to the flange 24. The groove 32; 5. The outer periphery of the outer cylinder 28 is welded to the surface of the flange 24. 6. The ends of the inner cylinder 26 may have a chamfer 'to facilitate mounting of the spool on the machine; 7. the outer periphery of the outer cylinder 28 and the surface of the flanges 24 The welding can be cut and rounded to facilitate smooth winding and rewinding processes. Another improvement to the present invention welds some support plates 34 between the outer periphery of the inner cylinder 26 and the inner periphery of the outer cylinder 28, as shown in FIG. The support plates 34 improve the strength of the outer cylinder 28 against deformation and determine that the inner cylinder 26 and the outer cylinder 28 are concentric. A further improvement of the present invention is to form the chamfer around the central opening 30 in the flanges 24, as shown in Figure 10, and to weld the ends of the outer cylinder 28 to the surface of the flanges 24. . Therefore, it is not necessary to weld between the end of the inner cylinder 26 and the surface of the flanges 24, since the end of the inner cylinder 28 is 11 - 200944462 when the spool is loaded with a fine metal wire. The parts are under a pressure against the surface of the flanges 24. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described in more detail with reference to the accompanying drawings in which FIG. 1 is a cross-sectional view of a conventional reel; FIG. 2 is an A-A cross-section of the reel of the present invention. Figure 3 is a schematic view showing the load distribution of the side pressure on the flange of a conventional spool; © Figure 4 is a schematic view showing the flange having the spool of the present invention Figure 5 is a side view of a spool of the present invention; Figure 6 is a detailed illustration of the weld between the outer perimeter of the inner cylinder and the inner periphery of the central bore on the flanges. Figure 7 is a detailed illustration of the weld between the inner periphery of the outer cylinder and the evenly distributed grooves on the flanges; Figure 8 is the outer periphery of the outer cylinder and the weld between the surfaces of the flanges DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Figure 9 is a cross-sectional view of a spool having a support device of the present invention; Figure 10 is a detailed illustration of the chamfer surrounding the central bore. [Main component symbol description] 10: Reel 1 2 : Core-12- 200944462 1 4 : Flange 20 : Reel 22 : Core 24 : Flange 2 6 : Internal cylinder ' 28 : External cylinder 3 0 : Center Hole 〇 32: uniform sentence distribution groove 3 4 : support plate d : inner diameter D : outer diameter Φ : outer diameter Η : height F2 : side pressure F 4 : side pressure