US20110290931A1 - Improved sawing wire spool - Google Patents

Improved sawing wire spool Download PDF

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Publication number
US20110290931A1
US20110290931A1 US13/131,102 US200913131102A US2011290931A1 US 20110290931 A1 US20110290931 A1 US 20110290931A1 US 200913131102 A US200913131102 A US 200913131102A US 2011290931 A1 US2011290931 A1 US 2011290931A1
Authority
US
United States
Prior art keywords
spool
flanges
core
debossed
debossed areas
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/131,102
Other languages
English (en)
Inventor
Luc Pauwels
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bekaert NV SA
Original Assignee
Bekaert NV SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bekaert NV SA filed Critical Bekaert NV SA
Assigned to NV BEKAERT SA reassignment NV BEKAERT SA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PAUWELS, LUC
Publication of US20110290931A1 publication Critical patent/US20110290931A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
    • B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
    • B65H75/04—Kinds or types
    • B65H75/08—Kinds or types of circular or polygonal cross-section
    • B65H75/14—Kinds or types of circular or polygonal cross-section with two end flanges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
    • B21C47/28—Drums or other coil-holders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
    • B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/50—Storage means for webs, tapes, or filamentary material
    • B65H2701/51—Cores or reels characterised by the material
    • B65H2701/511—Cores or reels characterised by the material essentially made of sheet material
    • B65H2701/5114—Metal sheets

Definitions

  • the invention relates to a spool for winding a fine metal wire on. More specifically the present invention relates to a spool made of metal sheet for winding a sawing wire on.
  • a conventional spool has a core and two flanges.
  • the two flanges are e.g. welded to either end of said core.
  • the core and the two flanges are made of thick metal sheets 1 to 6 mm made out of carbon steel.
  • An example of a fine metal wire to be wound on said spool is a sawing wire.
  • Sawing wire has a diameter of between 0.08 to 0.16 mm-0.12 mm is the most typical diameter—although sawing wire of 0.25 mm is known to exist. The trend is to even finer sawing wires in ever increasing lengths.
  • Sawing wire is used on loose abrasive sawing machines wherein the sawing wire drags slurry comprising a liquid carrier and abrasive particles into the progressing cut of the material to be sawn. This type of sawing machines is extensively used to cut silicon ingots for use in the semiconductor industry or for solar cell manufacturing.
  • the spool can be used also to wind fixed abrasive sawing wire on: then the abrasive particles are firmly attached to the wire and no carrier slurry is needed.
  • the spool can also be used to wind hose reinforcement wire on.
  • This kind of wire is braided or spiralled around an inner hose body for reinforcing the hose.
  • Such hoses are amongst other used in hydraulically activated machinery.
  • Hose wire generally has a diameter of 0.16 mm up to 0.25 mm and more.
  • each layer added to the spool exerts a pressure on the underlying layers.
  • This pressure is proportional to the force used to wind the wire on the spool and on the number of layers wound.
  • the pressure is transferred to the core of the spool as well as to the flanges. This pressure causes both flanges to be pushed outwardly. In extreme cases, the forces can be so immense that the flanges separate from the core or, even more extreme, the core simply collapses.
  • the most widely used spool for sawing wire is depicted in U.S. D 441772 and is made of thick metal sheet. Although it is sturdy, it can only be used once as the flanges are plastically deformed after only one use cycle. Moreover, the spool has not been designed to wind wires on of diameter 0.120 mm or less.
  • a spool made of metal sheet for winding metal wire on, said spool comprising a core and two flanges coupled to either end of said core, wherein the outer side of each of said flanges comprises multiple debossed areas that extend radial from said core.
  • said debossed areas are angularly evenly distributed around said core.
  • the flanges of the spool can for example be welded to the spool. Alternatively they can be brazed onto the core, or they can be attached with mechanical fastening means to the core. Still another possibility is that the flanges are foreseen with a collar at the centre hole. The rim of the collar is subsequently welded to the core. Or the collar can be made to slide into the core at the end and point welded there. The person skilled in the art may well find other methods to connect the core to the flange.
  • debossed areas that extend radial it is meant that the debossed areas have their longer dimension in a direction radial from the core to the outer rim of the flange.
  • ‘debossed area’ is meant an area in the metal sheet that has been plastically compressed. Hence, the area that is debossed is lower than the area surrounding it. This as opposed to ‘embossing’—as for example to strike the ‘head’ of a coin—wherein the area that is embossed is higher than the area surrounding it.
  • the lowering of the debossed area is solely due to the compression of the material.
  • the lowering of the area is not the consequence of taking away surface material in order to obtain the depressed area.
  • debossing is not the local deformation of the metal sheet as a consequence of stamping the metal sheet.
  • the thickness of the metal sheet largely remains the same and the negative of the imprint becomes visible at the side opposite to the stamping.
  • the area where debossing has taken place should barely be visible at the inner sides—i.e. the sides facing one another—of the flanges.
  • the inner sides of the flanges should be as smooth as possible in order not to lead to wiggling of the wire as it nears the side during winding.
  • the surface area of one single debossed area is upper limited by the tooling used: too high a surface area will result in less depth as the press used can only generate a maximum compressive force. In the lower limit, the area of one single debossed area should not be too small as otherwise the material will flow outside the compressed area with a less effective compression inside the area as a consequence.
  • the number of debossed areas is 4, preferably one debossed area every 90 degrees. In another embodiment the number of debossed areas is 6 preferably one debossed area at regular 60 degrees intervals. In a further embodiment the number of debossed areas is between 4 and 18.
  • the spool of the present invention provides a core having an outer diameter D 1 and two flanges having an outer diameter D 2 , whereby the free radius of said flanges is half of D 2 minus D 1 .
  • the spool is further characterized in that said debossed areas radially extend over at least 25% preferably at least 35%, most preferably at least 50% of said free radius. That is the largest dimension of the area measured in radial direction is at least 25%, preferably at least 35%, most preferably at least 50% of the free radius.
  • the free radius of said flanges is between 5 cm and 20 cm and the radial length of said debossed areas is between 2.5 cm and 10 cm.
  • the surface area of said debossed areas is in total more than 2% and less than 40% of the annular surface area between said core and the rim of one of said flanges.
  • the depth of said debossed areas is between 3% and 50% of the thickness of said flanges.
  • said flanges are between 2.5 mm and 6.0 mm thick and the depth of said debossed areas is between 0.2 mm and 1.25 mm.
  • said flanges are between 4.0 mm and 5.0 mm thick and said embossings are between 0.15 and 2.0 mm deep.
  • said flanges are 4.5 mm thick and said debossed areas are between 0.15 and 1.5 mm deep.
  • said debossed areas are substantially rectangular in shape, the longer side of said rectangular shape being in radial direction.
  • the width of said rectangular debossed areas is between 5 and 20 mm.
  • said debossed areas are truncated sectors in shape.
  • the sectors have their tips at the center of the spool flange.
  • Each of said sectors subtends an angle when seen from the centre of the spool.
  • the sum of the angles subtended by said truncated sectors is preferably between 10 and 180 degrees of arc.
  • one or both of said flanges are provided with one or two or more protruding drive studs for entrainment of said spool during use.
  • the drive studs engage with circular or semicircular cut-outs in the drive plate of the sawing machine. As the drive plate turns, the spool is driven by the plate through action of the studs.
  • the studs can be rings that are welded to the flange at the inside of the ring. Welding at the outside would lead to a weld burr at the foot of the stud that would prevent proper engagement of the stud in the drive holes.
  • Alternatively, and much preferred, is the use of a circular disk with two opposite, half-moon shaped cut-outs. The welding is done in the cut-outs from the outside which is much more convenient than having to weld in the confined ring space.
  • FIG. 1 shows a spool according to the invention
  • FIG. 2 is a side view of a spool according to the invention.
  • FIG. 3 is a B-B′ cross-sectional view of the flange of FIG. 2 ;
  • FIG. 4 is a side view of a spool according to an embodiment of the invention.
  • FIGS. 5 and 6 are side views of a spool according to specific embodiments of the invention.
  • FIG. 1 shows a first embodiment of a spool 10 according to the invention.
  • the spool 10 comprises a core 12 and two flanges 14 welded to either end of the core 12 .
  • the two flanges 14 are provided with six debossed areas 16 , evenly distributed angularly and extending radial from the core 12 .
  • the debossed areas 16 are substantially rectangular in shape.
  • Two protruding drive studs 18 are provided for entrainment of the spool 10 during use.
  • the two flanges may have a rim 20 , but this is not essential to the invention.
  • FIG. 2 is a side view of the first embodiment of the spool according to the invention, wherein the core 12 has an outer diameter D 1 and the two flanges 14 have an outer diameter D 2 .
  • D 1 is 156 mm
  • D 2 is 310 mm.
  • the free radius of the flanges is (D 2 ⁇ D 1 )/2 i.e. 77 mm.
  • the six debossed areas 16 have a substantially rectangular shape with a radial dimension of 40 mm i.e about 50% of the free radius is debossed.
  • the width of the areas is about 8 mm. About 3% of the free area is debossed.
  • FIG. 3 is a B-B′ cross-sectional view of the flange of FIG. 2 , illustrating that the flange 14 has a thickness ‘d’ and the debossed area 16 has a thickness ‘ ⁇ ’, wherein ‘ ⁇ ’ is between 50% and 97% of the thickness ‘d’ of the flange 14 implying that the steel sheet has been compressed 3 to 50%.
  • the thickness of the metal sheet ‘d’ was 4.5 mm and the thickness at the depressed area ‘ ⁇ ’ was 4.0 mm making the debossed areas 0.5 mm deep. It may be easier in practice to measure both thicknesses ‘d’ and ‘ ⁇ ’ and then derive the depth of the debossed areas rather than measuring the depth of the depressed areas directly.
  • Debossing is done by means of a hardened steel stamp having the desired area shape that is impressed into the flange by e.g. an impact press against an otherwise flat surface. This is done at normal temperatures and no other treatment is necessary. Important is that the stamping does not show significantly at the inner side of the flange: although a minor shade may be visible, there should not be a protrusion at the inner side of the flange. Such protrusion would be detrimental for the winding quality of the fine metal wire.
  • FIG. 3 also shows how the flange 14 is attached to the core 12 through two welding seams 15 and 17 at respectively the inner and outer side of the flange.
  • the studs 18 are made of a ring 27 mm in diameter and 12 mm high that is welded from the inside to the flange 14 .
  • FIG. 4 is a side view of a spool according to an alternative embodiment of the invention differing only from the first embodiment in that the protruding drive studs 18 have a different shape.
  • the studs are made of solid discs 27 mm in diameter and 12 mm high out of which two half-moon shaped parts are cut. The welding of the studs to the flange can be done much easier now as it can be done from the outside into the cut-outs.
  • FIGS. 5 and 6 show other preferred embodiments of the invention wherein the total surface area of the debossed areas 16 is larger than the surface area of the six debossed areas 16 shown in the previous figures.
  • FIG. 5 shows a flange having six debossed areas 16 in the form of truncated sectors.
  • the angle ‘a’ of one debossed area 16 is about 30 degrees of arc.
  • the sum of the angles subtended by said truncated sectors is about 180 degrees of arc.
  • About 23% of the annular surface area between core and rim is debossed.
  • FIG. 6 shows a specific embodiment of the invention wherein each of the two flanges comprise eighteen debossed areas 16 .
  • Tests were performed comparing the spool of the invention to a conventional spool only differing in that no debossed areas on the flanges are present.
  • the spools were according the dimensions and debossing as described for the first embodiment.
  • a conventional and an inventive spool were tested as follows: on each spool a fine wire of diameter 0.14 mm was wound at a controlled winding tension of about 3.5 Newton and a winding step of 0.15 mm. These are more stringent conditions than normally applied. Winding was stopped at a fine wire length of respectively 200, 400 and 800 km. At the stop, the inner flange width was accurately measured in axial direction with an insert gauge at the rim of the spool (at diameter D 2 ). At the rim of the spool, the deformation is maximal. The results shown in Table 1 display a lower deformation at the ends of the flanges for the spools of the invention when compared to the conventional spool.
  • Spools wound with 200 km of fine wire show no deformation compared to a 0.2 mm deformation of a conventional spool.
  • Spools wound with a 400 km fine wire show one third less deformation than conventional spools.
  • Spools wound with a 800 km fine wire show still an improvement all be it somewhat less. It is therefore conjectured that the results can even be more improved by extending the debossing over a longer radial length.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Storage Of Web-Like Or Filamentary Materials (AREA)
US13/131,102 2008-11-27 2009-11-10 Improved sawing wire spool Abandoned US20110290931A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP08170066 2008-11-27
PCT/EP2009/064821 WO2010060779A1 (en) 2008-11-27 2009-11-10 Improved sawing wire spool

Publications (1)

Publication Number Publication Date
US20110290931A1 true US20110290931A1 (en) 2011-12-01

Family

ID=40535638

Family Applications (1)

Application Number Title Priority Date Filing Date
US13/131,102 Abandoned US20110290931A1 (en) 2008-11-27 2009-11-10 Improved sawing wire spool

Country Status (9)

Country Link
US (1) US20110290931A1 (ja)
EP (1) EP2349888B1 (ja)
JP (1) JP5684716B2 (ja)
KR (1) KR101688667B1 (ja)
CN (1) CN102224094B (ja)
BR (1) BRPI0921859A2 (ja)
EA (1) EA016338B1 (ja)
MY (1) MY152516A (ja)
WO (1) WO2010060779A1 (ja)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100252672A1 (en) * 2009-04-02 2010-10-07 Sonoco Development Inc. Spool with drive feature
US20180170708A1 (en) * 2015-07-22 2018-06-21 Max Co., Ltd. Reel
WO2021118615A1 (en) * 2019-12-09 2021-06-17 Essentium, Inc. Split spool assembly for a three-dimensional printer
US11420843B2 (en) * 2015-08-10 2022-08-23 Dexerials Corporation Reel member, film housing body, and method for manufacturing reel member

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6024659B2 (ja) * 2011-07-19 2016-11-16 旭硝子株式会社 薄板ガラスの巻取装置および収容装置
CN102897601A (zh) * 2011-07-28 2013-01-30 浙江思博恩新材料科技有限公司 一种收放线轮
DE102017111831B4 (de) * 2017-05-30 2019-01-10 Amphenol-Tuchel Electronics Gmbh Bandlagervorrichtung

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US1448355A (en) * 1921-11-30 1923-03-13 American Pulley Co Wheel disk and the like
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USD563207S1 (en) * 2006-09-25 2008-03-04 Tokusen Engineering Co., Ltd. Cable drum

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US1391372A (en) * 1919-10-30 1921-09-20 Central Metal Products Corp Film-reel
US1417313A (en) * 1921-07-12 1922-05-23 William F Gammeter Film reel
US1448355A (en) * 1921-11-30 1923-03-13 American Pulley Co Wheel disk and the like
US1981139A (en) * 1928-06-26 1934-11-20 Western Electric Co Reel
US2177152A (en) * 1936-07-13 1939-10-24 Oscar A Ross Motion picture film reel
US2601660A (en) * 1948-07-06 1952-06-24 Dominion Magnesium Ltd Spool construction
US2973159A (en) * 1959-08-17 1961-02-28 Thomas S Kulka Friction reducing tape reel
US5106031A (en) * 1991-03-26 1992-04-21 Tokusen Kogyo Company Limited Reel for winding metallic wire
US5474254A (en) * 1994-11-08 1995-12-12 Faulkner Fabricators, Inc. Spool and method of making same
US6959892B2 (en) * 2001-09-19 2005-11-01 Tokusen Engineering Co., Ltd. Reel for fine metal wire and method of manufacturing same
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USD563207S1 (en) * 2006-09-25 2008-03-04 Tokusen Engineering Co., Ltd. Cable drum

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Publication number Priority date Publication date Assignee Title
US20100252672A1 (en) * 2009-04-02 2010-10-07 Sonoco Development Inc. Spool with drive feature
US20180170708A1 (en) * 2015-07-22 2018-06-21 Max Co., Ltd. Reel
US10717626B2 (en) * 2015-07-22 2020-07-21 Max Co., Ltd. Reel with information display portions
US11180342B2 (en) * 2015-07-22 2021-11-23 Max Co., Ltd. Reel
US11401131B2 (en) * 2015-07-22 2022-08-02 Max Co., Ltd. Reel with indicator information
US11420843B2 (en) * 2015-08-10 2022-08-23 Dexerials Corporation Reel member, film housing body, and method for manufacturing reel member
WO2021118615A1 (en) * 2019-12-09 2021-06-17 Essentium, Inc. Split spool assembly for a three-dimensional printer

Also Published As

Publication number Publication date
CN102224094B (zh) 2015-06-03
EA016338B1 (ru) 2012-04-30
MY152516A (en) 2014-10-15
EP2349888B1 (en) 2013-01-16
WO2010060779A1 (en) 2010-06-03
KR101688667B1 (ko) 2016-12-21
JP5684716B2 (ja) 2015-03-18
EA201100844A1 (ru) 2011-10-31
JP2012509824A (ja) 2012-04-26
EP2349888A1 (en) 2011-08-03
BRPI0921859A2 (pt) 2015-12-29
CN102224094A (zh) 2011-10-19
KR20110084428A (ko) 2011-07-22

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Legal Events

Date Code Title Description
AS Assignment

Owner name: NV BEKAERT SA, BELGIUM

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PAUWELS, LUC;REEL/FRAME:026342/0013

Effective date: 20091112

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION