Capillary Wicking Device Metallic Core Binder Removal

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Solution Overview

Problem

Existing wicking devices have limited initial drainage capacity due to a hydrophobic binder coating on glass fiber yarns, which reduces their effectiveness in drawing away excess water, and the thermoplastic core is prone to damage from high temperatures needed to remove this binder.

Innovation Solution

A wicking device featuring a porous, heat-resistant metallic core surrounded by a continuous layer of glass fiber yarns and an outer jacket of interwoven glass fiber yarns, with the entire assembly being heat-treated to remove the binder and organic matter, creating a passageway for enhanced fluid flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If heat treatment is applied to remove the hydrophobic binder coating on glass fiber yarns, then the wicking capacity is improved, but the thermoplastic core is damaged by high temperatures

Engineering Contradiction:

Improvewicking capacityVSAvoidcore integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the material parameter of the core from thermoplastic to heat-resistant material (such as metal or ceramic), enabling the device to withstand high temperatures during binder removal heat treatment. This parameter change allows the core to survive the thermal process needed to improve wicking capacity, resolving the contradiction between achieving high wicking capacity through heat treatment and maintaining core integrity.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If a thermoplastic core is used to provide a passageway for fluid flow, then the device structure is simple, but the core is prone to damage from high temperatures needed to remove the binder

Engineering Contradiction:

Improvecore structureVSAvoidheat damage

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the thermal resistance parameter of the core material from low (thermoplastic) to high (heat-resistant material like metal or ceramic). This allows the core to maintain its simple passageway structure while withstanding the high temperatures required for binder removal, thus resolving the contradiction between structural simplicity and heat resistance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite construction where the core is made of heat-resistant material (metal or ceramic) while the wicking layers use glass fiber yarns. This composite approach combines the structural simplicity and fluid conductivity of a core passageway with the heat resistance of specialized materials, resolving the contradiction between simple structure and heat damage susceptibility.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the binder coating remains on the glass fiber yarns, then the device structure is intact during manufacture, but the initial drainage capacity is reduced due to hydrophobic properties

Engineering Contradiction:

Improveyarn structureVSAvoiddrainage capacity

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent applies preliminary heat treatment during the manufacturing process to remove the hydrophobic binder coating from the glass fiber yarns before the device is put into service. This preliminary action eliminates the harmful hydrophobic properties that reduce drainage capacity, while the heat-resistant core ensures the device can withstand this necessary treatment without damage.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful effect of high temperature (which could damage the core) into a beneficial process by using the heat to remove the hydrophobic binder coating. The heat-resistant core material allows the temperature that would normally be harmful to be applied beneficially to improve wicking capacity by eliminating the hydrophobic barrier.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Significantly improves the immediate wicking capacity and durability of the device by eliminating the binder and protecting the core from heat damage, allowing for efficient water drainage and environmental resistance.

Implementation Method 1

passive capillary wicking device to transfer excess water and water based fluids

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

heat-treated to remove the binder and organic matter

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS8100604B1Passive capillary wicking device

Publication Date: 2012.01.24 DAVLYN MANUFACTURING CO LLC

AI summary

A wicking device is an elongated tubular assembly having opposing ends and formed of an elongated, porous, tubular, heat resistant, metallic core suggestedly of interwoven resilient wire, a wicking layer of glass fiber yarns extending generally longitudinally along the outer surface of the metallic core, at least substantially surrounding the metallic core, and an exterior of interwoven glass fiber yarns forming an elongated tubular outer jacket running the length of the device surrounding the wicking layer of glass fiber yarns and the metallic core. The assembly is stripped of organic materials following assembly as part of the manufacturing process, preferably by heating the assembly.