Modularized wire cutting and flying die
By designing a modular tangent flying wire die, the problems of precision and efficiency in the aluminum foil wrapping process of traditional dies are solved, achieving high-precision, low-cost aluminum foil wrapping, and adapting to different sizes with flexibility and quick switching.
Patent Information
- Application Number
- CN202511877185.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-12
- Publication Date
- 2026-02-13
AI Technical Summary
Traditional molds present a contradiction between geometric precision and forming control during the aluminum foil coating process, resulting in poor aluminum foil coating quality. Furthermore, it is difficult to balance multi-process integration and processing precision, leading to problems such as wrinkles, seams, and misalignment.
The modular tangential flying wire mold is adopted. After the covering material is folded into a preset arc shape, it enters the large hole at the rear end of the forming section and extends forward along the inner wall of the channel. The core wire is inserted and fixed from the large hole at the rear end. Finally, it fits tightly with the core wire under the double constraint of the inner wall of the through cavity, ensuring no wrinkles, no seams and no deviation. The processing is completed in one clamping.
It significantly improves processing precision and efficiency, reduces production costs, achieves accuracy and consistency in aluminum foil coating, is highly adaptable, and shortens the sample development cycle and mass production response time.
Smart Images
Figure CN121528656A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of modular tangential flying wire mold technology, and specifically to a modular tangential flying wire mold. Background Technology
[0002] In the manufacturing process of modern high-frequency transmission cables (such as RF feeders for 5G communication base stations and precision cables for aerospace equipment), the quality of the metal shielding layer is a key factor determining the electromagnetic shielding effectiveness and signal transmission stability of the cable. Aluminum foil, due to its high conductivity, lightweight, and cost advantages, has become one of the most commonly used shielding materials. However, traditional wrapping technology faces the following technical bottlenecks in practical applications: I. The contradiction between geometric accuracy and molding control Existing mold cavity structures mostly adopt a "straight-through" design, which guides the aluminum foil to wrap the core wire through a single linear channel. This structure has an inherent defect: the deformation process of the aluminum foil from a planar state to a curved surface lacks gradual guidance, resulting in stress concentration at the edges and making it prone to wrinkles (industry statistics show that the incidence of such defects on high-speed production lines is as high as 12%-15%). II. Balancing Multi-Process Integration with Machining Precision To improve the coating quality, some companies have adopted a two-stage mold of "pre-bending + main forming". However, this solution has caused new problems: the cumulative installation error of the mold components will cause the aluminum foil inlet angle to deviate from the design value by 3°-5°, resulting in a spiral seam in the final coating layer.
[0003] The above background information is disclosed only to assist in understanding the inventive concept and technical solution of this invention. It does not necessarily belong to the prior art of this patent application, nor does it necessarily provide technical teachings. In the absence of clear evidence, the novelty and inventiveness of the above application shall be deemed to be incomplete. Summary of the Invention
[0004] To address the aforementioned technical issues, this invention proposes a modular tangential wire die. The covering material, folded into a preset arc shape, enters through a large hole at the rear end of the forming section and extends forward along the inner wall of the channel. The core wire passes through the large hole at the rear end of the forming section and is axially fixed. Finally, under the dual constraints of the inner wall of the through cavity and the core wire, the covering material tightly adheres to the outer circumference of the core wire, completing the covering process. This ensures accurate direction, consistent fit, and no wrinkles, seams, or offsets. The processing of "large hole at the rear end + through seam + small hole at the front end" can be completed in one clamping, significantly improving processing accuracy and efficiency.
[0005] To achieve the above objectives, the technical solution of the present invention is as follows: On one hand, the present invention provides a modular tangential flying wire die, comprising: a forming section, wherein the forming section is provided with a through cavity, the through cavity comprising: The large hole at the rear end is shaped to match and connect with the arc-shaped transition end of the fixed section; The shape of the small hole at the front end is adapted to the outer diameter of the core wire to be covered and the thickness parameters of the covering material. A through-slit extends radially and connects the large rear hole with the small front hole, the width of which matches the thickness of the covering material.
[0006] This invention proposes a modular tangential wire die. The covering material, after being folded into a preset arc shape, enters through a large hole at the rear end of the forming section and then extends forward along the inner wall of the channel. The core wire passes through the large hole at the rear end of the forming section and is axially fixed. Finally, under the dual constraints of the inner wall of the through cavity and the core wire, the covering material tightly adheres to the outer circumference of the core wire to complete the covering. This ensures accurate direction, consistent fit, and no wrinkles, seams, or offsets. The processing of "large hole at the rear end + through seam + small hole at the front end" can be completed in one clamping, which greatly improves the processing accuracy and efficiency.
[0007] As a preferred technical solution, the radius of curvature of the large hole at the rear end is equal to the radius of curvature of the arc-shaped transition end of the fixed section.
[0008] As a preferred technical solution, the front end hole includes: a waist-shaped hole, wherein the waist-shaped hole is designed to have a width greater than the core wire size by 10% and a height greater than the core wire size by 15%.
[0009] As a preferred technical solution, the through seam is an arc-shaped through seam, the width of which is adapted to the thickness of the covering material, and extends from the edge of the small hole at the front end to the large hole at the rear end, forming a "6" shaped cavity structure.
[0010] As a preferred technical solution, the front end hole is formed by offsetting a baseline, and the baseline satisfies the following geometric conditions: The baseline is a circular arc; The center of the arc is located within a range of ≥0.3mm above the center line of the waist-shaped hole; The arc is tangent to the semicircle on one side of the waist-shaped hole; The arc extends by a preset angle after the tangent point and then transforms into an extended parallel line segment.
[0011] As a preferred technical solution, the top of the fixed section is provided with a through slot extending along its length.
[0012] As a preferred technical solution, the following are included: The base has a through-hole mounting slot on its top; The fixed section is detachably assembled into the assembly slot and is used to guide and initially shape the covering material; The molding section is detachably assembled into the mounting slot and docked with the fixing section; wherein, the cross-sectional profile of the mounting slot is adapted to the bottom shape of the fixing section and the molding section; one end of the mounting slot is provided with a limiting surface for fitting with the end faces of the fixing section and the molding section; the fixing section, the molding section and the base together form a covering channel for the core wire and the covering material to pass through.
[0013] As a preferred technical solution, the fixed section includes, in sequence along the feeding direction of the coating material: The inlet limiting end is provided with an opening for positioning the width of the covering material; The arc-shaped transition end has an arc-shaped surface with a predetermined radius of curvature, which matches the radius of curvature of the large hole at the rear end, so as to make the covering material transition smoothly.
[0014] As a preferred technical solution, for the covering material of different widths, the adaptation is achieved by replacing the fixed section of the inlet limiting end with one of different sizes, while the radius of curvature of the arc-shaped transition end remains unchanged.
[0015] As a preferred technical solution, the base and the fixing section are integrally formed by 3D printing of engineering plastic; the forming section is integrally formed by wire cutting of metal material.
[0016] The high-frequency, low-loss communication cable provided by this invention has the following beneficial effects: The covering material, folded into a preset arc shape, enters through the large hole at the rear end of the forming section and extends forward along the inner wall of the channel. The core wire passes through the large hole at the rear end of the forming section and is axially fixed. Finally, under the dual constraints of the inner wall of the through cavity and the core wire, the covering material tightly adheres to the outer circumference of the core wire to complete the covering. This ensures accurate direction, consistent fit, and no wrinkles, seams, or offsets. The processing of "large hole at the rear end + through seam + small hole at the front end" can be completed in one clamping, greatly improving processing accuracy and efficiency. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the structure of a modular tangential flying wire die provided by the present invention; Figure 2 This is a structural schematic diagram of a modular tangential flying wire mold provided by the present invention from another perspective; Figure 3 This is a structural schematic diagram of a modular tangential flying wire mold provided by the present invention from another perspective; Figure 4 This is a structural schematic diagram of a modular tangential flying wire mold provided by the present invention from another perspective; Among them, 1-front end small hole; 2-forming section; 3-rear end large hole; 4-base; 5-fixing section; 6-inlet limiting end; 7-arc transition end. Detailed Implementation
[0018] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0019] Traditional aircraft molds rely on multiple folding processes of metal sheets. First, grooves are folded to secure the aluminum foil covering material. Then, the sheet is gradually bent from a horizontal position into an arc shape, ultimately forming a conical cavity. An opening is retained in the structure to guide the aluminum foil covering material as it folds in a predetermined direction. This design addresses the shortcomings of complex processing and limited applicability.
[0020] like Figure 1-4 As shown, the present invention provides a modular tangential flying wire die, comprising: a forming section 2, wherein the forming section 2 is provided with a through cavity, the through cavity comprising: The rear end large hole 3 is shaped to match and connect with the arc-shaped transition end 7 of the fixed section 5; The front end small hole 1 is shaped to match the outer diameter of the core wire to be covered and the thickness parameters of the covering material. A through-slit extends radially and connects the large rear hole 3 with the small front hole 1, the width of which matches the thickness of the covering material.
[0021] This invention proposes a modular tangential wire die. The covering material, after being folded into a preset arc shape, enters through a large hole at the rear end of the forming section and then extends forward along the inner wall of the channel. The core wire passes through the large hole at the rear end of the forming section and is axially fixed. Finally, under the dual constraints of the inner wall of the through cavity and the core wire, the covering material tightly adheres to the outer circumference of the core wire to complete the covering. This ensures accurate direction, consistent fit, and no wrinkles, seams, or offsets. The processing of "large hole at the rear end + through seam + small hole at the front end" can be completed in one clamping, which greatly improves the processing accuracy and efficiency.
[0022] Preferably, such as Figure 1-4 As shown, the radius of curvature of the large rear hole is equal to the radius of curvature of the arc-shaped transition end of the fixed section.
[0023] Preferably, such as Figure 1-4 As shown, the front end small hole 1 includes: a waist-shaped hole, the waist-shaped hole being designed with a width greater than the core wire size by 10% and a height greater than the core wire size by 15%.
[0024] Preferably, such as Figure 1-4 As shown, the through seam is an arc-shaped through seam, the width of which is adapted to the thickness of the covering material, and extends from the edge of the front small hole 1 to the rear large hole 3, forming a "6" shaped cavity structure.
[0025] Preferably, such as Figure 1-4 As shown, the front end hole 1 is formed by offsetting a baseline, and the baseline satisfies the following geometric conditions: The baseline is a circular arc; The center of the arc is located within a range of ≥0.3mm above the center line of the waist-shaped hole; The arc is tangent to the semicircle on one side of the waist-shaped hole; The arc extends by a preset angle after the tangent point and then transforms into an extended parallel line segment.
[0026] Preferably, such as Figure 1-4 As shown, the top of the fixed section 5 is provided with a through slot extending along its length.
[0027] Preferably, such as Figure 1-4 As shown, it includes: The base 4 has a through-type mounting slot on its top; Fixed section 5 is detachably assembled into the assembly slot and is used to guide and initially shape the covering material; The molding section 2 is detachably assembled into the mounting slot and docked with the fixing section 5; wherein, the cross-sectional profile of the mounting slot is adapted to the bottom shape of the fixing section 5 and the molding section 2; one end of the mounting slot is provided with a limiting surface for fitting with the end faces of the fixing section 5 and the molding section 2; the fixing section 5, the molding section 2 and the base 4 together form a covering channel for the core wire and the covering material to pass through.
[0028] Preferably, such as Figure 1-4 As shown, the fixed section 5, along the feeding direction of the coating material, includes the following in sequence: The inlet limiting end 6 is provided with an opening for positioning the width of the covering material; The arc-shaped transition end 7 has an arc-shaped surface with a predetermined radius of curvature, which matches the radius of curvature of the large hole at the rear end, so as to make the covering material transition smoothly.
[0029] Preferably, such as Figure 1-4 As shown, for the covering material of different widths, the adaptation is achieved by replacing the fixed section of the inlet limiting end 6 with a different size, while the radius of curvature of the arc transition end 7 remains unchanged.
[0030] Preferably, such as Figure 1-4 As shown, the base 4 and the fixing section 5 are integrally formed by 3D printing of engineering plastic; the forming section 2 is integrally formed by wire cutting of metal material.
[0031] This invention proposes a novel "modular" wire-cut splicing aircraft model, which adopts a manufacturing process combining wire cutting and 3D printing to decompose the original one-piece metal sheet structure into three independent parts: base, fixing section and forming section. The three parts are assembled to form a complete covering device, and the covering material is preferably aluminum foil.
[0032] The base 4 is integrally molded using low-cost engineering plastics such as PLA or ABS through 3D printing. A through-type assembly slot is provided on its top, with the cross-sectional profile of the slot matching the bottom shape of the fixed section 5 and the molding section 2 (gap ≤ 0.1mm). The assembly slot extends axially along the fixture. The front end of the base 4 has a closed limiting surface, and the rear end is an open insertion port. During assembly, the fixed section 5 and the molding section 2 are inserted into the assembly slot from the open port at the rear end of the base. The fit between the assembly slot and the module's shape directly restricts their left-right radial movement. The closed limiting surface at the front end of the assembly slot fits against the front end faces of the fixed section and the molding section, forming an axial limit that prevents the module from moving forward. During operation, the forward traction force generated by the core wire and aluminum foil moving forward along the internal cavity of the fixture forms a reverse constraint with the limiting force at the front end of the assembly slot. Ultimately, the base 4, fixed section 5, and molding section 2 are securely joined without loosening, eliminating the need for additional fasteners and saving costs.
[0033] Both the fixing section 5 and the base 4 are integrally molded from the same material, forming a long strip. The fixing section 5, along the aluminum foil feeding direction, includes an inlet limiting end 6 and an arc-shaped transition end 7, with a through-hole at the top. The inlet limiting end 6 is a rectangular opening, its length slightly greater than the width of the aluminum foil, used to position the foil. The end face of the arc-shaped transition end 7 is a semi-circular arc structure with a fixed radius of curvature, and its arc length is consistent with the length of the rectangular opening, ensuring a smooth transition along the arc surface after the aluminum foil passes through the opening, avoiding creases or deformation. The top slot extends through the entire length of the fixing section, but its length is less than the internal arc-shaped channel, facilitating visual alignment and manual adjustment during threading. For aluminum foils of different widths, only the size of the rectangular opening of the fixing section needs to be adjusted, while keeping the semi-circular radius of curvature of the arc-shaped transition end 7 constant. Since the curved transition ends of all fixed sections match the large rear hole of the forming section, fixed sections of different specifications can be used in combination with the same forming section and base, enabling rapid switching between products of multiple sizes without replacing the entire fixture. Because the aluminum foil specifications are relatively fixed, the fixed sections can be designed in a series, with the rectangular openings of the inlet limiting end 6 graded at 0.5mm intervals to form a standard parts library for quick selection.
[0034] Forming section 2 is the most important component in aluminum foil forming. To ensure that the dimensions will not deform due to wear, 3D printing technology and materials were abandoned, and a softer metal material was used instead, which was integrally formed by wire cutting. Its core structure is a "6"-shaped through cavity, which is formed by the coaxial connection of a large rear hole 3 and a small front hole 1. The large rear hole 3 is an arc-shaped hole, and its radius of curvature is exactly the same as the radius of curvature of the arc transition end 7 of the fixed section 5, ensuring that the arc transition end 7 of the fixed section 5 can fit seamlessly with the large rear hole 3, realizing a stepless transition of the aluminum foil path. The small front hole 1 is an oblong hole with semicircles at both ends and a rectangle in the middle. Its size matches the wire diameter of the core wire to be covered (the thickness of the aluminum foil needs to be added), which is used to limit the axial position of the core wire and the aluminum foil to avoid misalignment. An arc-shaped through-slit extends radially from one side of the front small hole 1. The width of the through-slit is adapted to the thickness of the aluminum foil (usually 0.45mm to avoid dust accumulation and blockage). The through-slit extends from the edge of the front small hole 1 to the rear large hole 3, connecting the rear large hole 3 with the front small hole 1 to form a "6" shaped structure. This structure is specifically designed for wire EDM, and can complete the processing of "front small hole + radial through-slit + rear large hole" in one clamping, greatly improving processing accuracy and efficiency. After the aluminum foil is folded into a preset arc shape at the arc transition end of the fixed section, it enters through the rear large hole 3 of the forming section and then extends forward along the inner wall of the channel. The core wire passes through the rear large hole of the forming section and is axially fixed. Finally, under the dual constraints of the inner wall of the channel and the core wire, the aluminum foil is tightly adhered to the outer circumference of the core wire to complete the wrapping, ensuring accurate orientation, consistent fit, and no wrinkles or deviations.
[0035] This invention proposes a modular tangential wire die manufacturing process, comprising the following steps: First, both the aluminum foil and the core wire pass through the fixing section 5. Here, the aluminum foil is confined within the rectangular opening of the 3D-printed fixing section 5 and pre-folded into a semi-circular shape along the arc transition end 7 between the rear large hole 3 and the fixing section 5, achieving initial shaping. Subsequently, the cable, distributed vertically (core wire on top, arc-shaped aluminum foil on the bottom), enters the wire cutting forming section. The aluminum foil is introduced from its rear large hole 3, guided by the internal contour of the "6"-shaped cavity, wrapping upwards around the core wire and advancing forward to the front small hole 1, ultimately completing the tight and precise full coverage of the core wire by the aluminum foil. The covered cable continues to be compacted and shaped by the positioning mold, and finally reinforced by wrapping with Mylar tape, thus ending the entire direct wrapping process. The edges of the rear large hole are rounded to prevent scratching the aluminum surface. The design of the small hole 1 at the front end directly affects the forming effect of the mold on the aluminum foil. First, a waist-shaped hole with semicircles at both ends and a rectangle in the middle is provided (the size of the waist-shaped hole is designed according to the size of the aluminum foil after covering the core wire, and the principle is that the width is greater than the core wire size by 10% and the height is greater than the core wire size by 15%). Then, an arc is made at a point 0.3mm above the center line of the waist-shaped hole (to provide space for the gap through which the aluminum foil passes), tangent to the left circle of the waist-shaped hole, stopping at an angle of 25° and extending a parallel line (to allow the aluminum foil to enter the pointed mold at a certain angle for easy forming). This extended parallel line is equidistant from 0.45mm (for the aluminum foil to pass through).
[0036] This invention provides a simple, flexible, and low-cost aluminum foil-wrapping material direct wrapping fixture, which aims to solve the problems of cumbersome processing, poor adaptability, and high cost of traditional one-piece metal folding aircraft molds in the existing aluminum foil-wrapping material direct wrapping process. At the same time, it ensures that the aluminum foil-wrapping material is accurately wrapped along a preset path, and finally achieves the same or even better wrapping effect as traditional aircraft molds.
[0037] This invention provides a modular tangential flying wire die, which also has the following technical advantages: 1. After the large hole at the rear end and the arc-shaped transition end of the fixed section are folded into a preset arc shape, the material enters through the large hole at the rear end of the forming section and then extends forward along the inner wall of the channel. The core wire passes through the large hole at the rear end of the forming section and is axially fixed. Finally, under the dual constraints of the inner wall of the through cavity and the core wire, the covering material is tightly attached to the outer circumference of the core wire to complete the covering. This ensures accurate direction, consistent fit, and no wrinkles or deviations. The processing of "large hole at the rear end + through seam + small hole at the front end" can be completed in one clamping, which greatly improves the processing accuracy and efficiency. 2. Significant cost and processing advantages: The combination of "3D printing + wire cutting" replaces the complex metal folding process, which greatly reduces the manufacturing difficulty, production cost and subsequent maintenance cost of the fixture; 3. Modular design with strong versatility: By decomposing the fixture into three independent modules—base, fixing section, and forming section—the core functional units are separated. The fixing section can be designed in series for different aluminum foil widths (e.g., in 0.5mm increments) and flexibly combined with the universal base and forming section, achieving "one mold for multiple uses." This effectively solves the pain point of traditional fixtures only adapting to a single size, significantly improving process adaptability and flexibility. 4. Overall Improvement in Production Efficiency: This design not only shortens the sample development cycle and trial-and-error costs, but also enables instantaneous switching of product dimensions in mass production by quickly changing fixed sections, avoiding downtime caused by changing and adjusting the overall fixture, thereby significantly improving production efficiency and market responsiveness.
[0038] It is understood that this invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this invention. Furthermore, under the teachings of this invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this invention. Therefore, this invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are protected by this invention. Furthermore, under the teachings of this invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this invention. Therefore, this invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the scope of protection of this invention.
Claims
1. A modular tangential flying wire die, characterized in that, include: The forming section, wherein the forming section is provided with a through cavity, the through cavity comprising: The large hole at the rear end is shaped to match and connect with the arc-shaped transition end of the fixed section; The shape of the small hole at the front end is adapted to the outer diameter of the core wire to be covered and the thickness parameters of the covering material. A through-slit extends radially and connects the large rear hole with the small front hole, the width of which matches the thickness of the covering material.
2. The modular tangential flying wire mold according to claim 1, characterized in that, The radius of curvature of the large rear end hole is equal to the radius of curvature of the arc-shaped transition end of the fixed section.
3. The modular tangential flying wire mold according to claim 1, characterized in that, The front end hole includes an oblong hole, the oblong hole being designed to have a width greater than the core wire size by 10% and a height greater than the core wire size by 15%.
4. The modular tangential flying wire mold according to claim 1, characterized in that, The through seam is an arc-shaped through seam, the width of which is adapted to the thickness of the covering material, and extends from the edge of the small hole at the front end to the large hole at the rear end, forming a "6" shaped cavity structure.
5. The modular tangential flying wire mold according to claim 1, characterized in that, The small hole at the front end is formed by offsetting a baseline, and the baseline satisfies the following geometric conditions: The baseline is a circular arc; The center of the arc is located within a range of ≥0.3mm above the center line of the waist-shaped hole; The arc is tangent to the semicircle on one side of the waist-shaped hole; The arc extends by a preset angle after the tangent point and then transforms into an extended parallel line segment.
6. The modular tangential flying wire die according to any one of claims 1-5, characterized in that, The top of the fixed section is provided with a through slot extending along its length.
7. The modular tangential flying wire mold according to claim 1, characterized in that, include: The base has a through-hole mounting slot on its top; The fixed section is detachably assembled into the assembly slot and is used to guide and initially shape the covering material; The molding section is detachably assembled into the mounting slot and docked with the fixing section; wherein, the cross-sectional profile of the mounting slot is adapted to the bottom shape of the fixing section and the molding section; one end of the mounting slot is provided with a limiting surface for fitting with the end faces of the fixing section and the molding section; the fixing section, the molding section and the base together form a covering channel for the core wire and the covering material to pass through.
8. The modular tangential flying wire die according to claim 7, characterized in that, The fixed section, along the feeding direction of the coating material, includes, in sequence: The inlet limiting end is provided with an opening for positioning the width of the covering material; The arc-shaped transition end has an arc-shaped surface with a predetermined radius of curvature, which matches the radius of curvature of the large hole at the rear end, so as to make the covering material transition smoothly.
9. The modular tangential flying wire die according to claim 8, characterized in that, For the covering material of different widths, adaptation is achieved by replacing the fixing section of the inlet limiting end with one of different sizes, while the radius of curvature of the arc transition end remains unchanged.
10. The modular tangential flying wire die according to claim 4, characterized in that, The base and the fixing section are integrally formed from engineering plastics using 3D printing; the forming section is integrally formed from metal material using wire cutting technology.