Coated Wire Production with Defect Marking for Higher Yield
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Solution Overview
Problem
The existing methods for producing wire elements with multiple layers are inefficient, leading to increased production time, defect occurrence, and waste due to the need for cutting coated wires to remove defects, which also results in higher production costs and equipment complexity.
Innovation Solution
A method involving quality control processes to identify and mark defects in wire elements, using laser ablation to manipulate layers and introduce repeating units along the wire, allowing for efficient cutting into wire elements without discarding defect-free segments, thereby reducing production time and costs while ensuring defect-free wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first coated wire is cut to remove defects, then defect-free segments are obtained, but production time increases and production yield decreases
Solution Approach 1:
The patent applies preliminary action by marking defects on the first coated wire before the coating process is complete. This allows the coating line to continue running without stopping, and defects are identified and marked in advance so that only the necessary portions are discarded after coating, rather than cutting and discarding segments during the coating process.
Solution Approach 2:
The coating process itself serves to protect the wire while defect identification is performed. The system uses the coating process to both protect the wire and enable defect detection through marking, eliminating the need for separate inspection and cutting operations that would reduce productivity.
2Reliability
If the first coated wire is cut to remove defects, then defect-free segments are obtained, but production time increases due to starting and stopping equipment
Solution Approach 1:
Defects are marked during the coating process itself, allowing the equipment to run continuously without stopping for inspection or cutting operations. The marking is performed preliminarily so that defect removal can be done efficiently after the continuous coating process completes.
Solution Approach 2:
The coating process continues uninterrupted while defect marking is performed. The system maintains continuous operation of the coating line, eliminating the start-stop cycles that would otherwise be required to inspect, cut, and reposition wire segments for defect removal.
3Productivity
If additional production equipment is added to reduce production time, then productivity increases, but production costs and equipment complexity increase
Solution Approach 1:
The coating line is designed to perform multiple functions: it both coats the wire and enables defect identification through marking. This multi-functionality eliminates the need for separate inspection and cutting equipment, maintaining simplicity while improving productivity.
Solution Approach 2:
The defect identification and marking functions are merged into the existing coating process. Rather than adding separate inspection and cutting equipment, the system combines these functions into the coating line itself, reducing overall equipment complexity while maintaining high productivity.
4Reliability
If the first coated wire is cut to remove defects, then defect-free segments are obtained, but energy consumption increases
Solution Approach 1:
Defects are marked during the coating process, allowing continuous operation without energy-intensive stopping and starting of equipment. The marking is done preliminarily so that minimal cutting is required afterward, reducing the energy consumption associated with repeated equipment startup and operation cycles.
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
This method decreases production time and defect occurrence, increases the yield of defect-free wire elements, reduces energy consumption, and simplifies equipment complexity, enabling the use of high-quality wire elements in medical devices with improved reliability and extended life expectancy.
Implementation Method 1
using laser ablation to manipulate layers and introduce repeating units along the wire
Data Source
AI summary
One aspect is a method for producing a plurality of wire elements, including providing a metal wire, coating the metal wire with a first layer to obtain a first coated wire, subjecting the first coated wire to a first quality control process, marking any first defects identified in the first quality control process, coating the first coated wire with a further layer to obtain a further coated wire, and cutting the further coated wire to obtain a plurality of wire elements. Prior to cutting the further coated wire to obtain the plurality of wire elements, a first length of the first coated wire is less than 10% longer than a further length of the further coated wire.