Conveying Wire Jacket Attachment via Segmented Injection Molding
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Solution Overview
Problem
Existing methods for producing conveying wires with disc-shaped members fail to achieve a permanent and secure attachment of the outer jacket to the fiber wire and disc-shaped conveying members, leading to potential damage from particulate minerals and moisture ingress, which can cause breakage and mold formation.
Innovation Solution
A method involving continuous injection molding to directly connect disc-shaped conveying members onto the outer jacket or fiber wire, while keeping the wire tight during processing to prevent strand opening, and using annular beads or soft thermoplastic elastomers like Santoprene for enhanced adhesion and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disc-shaped conveying members are fastened directly on an outer sheath by injection moulding, then a permanent connection is achieved, but the attachment strength is insufficient and components may detach under stress
Solution Approach 1:
The outer jacket is divided into separate sections with opposing end parts that extend under the disc-shaped conveying members. This segmentation allows the end parts to wrap around and secure the discs, creating a multi-point attachment system rather than a single continuous connection, thereby significantly improving attachment strength and reliability.
Solution Approach 2:
The opposing end parts of the outer jacket sections act as intermediary elements that physically connect the disc-shaped conveying members to the fiber wire core. These end parts extend under the discs and are connected to the core, serving as a mediator that transfers and distributes mechanical stress, ensuring secure attachment while maintaining flexibility.
2Device complexity
If the fiber wire is left exposed, then the structure remains simple, but the wire is vulnerable to damage from particulate minerals and moisture ingress causing breakage and mold formation
Solution Approach 1:
An outer jacket made of flexible material is applied over sections of the fiber wire core. This thin film protective layer shields the wire from harmful factors such as particulate minerals and moisture while maintaining the flexibility needed for conveyor operation. The jacket acts as a barrier without significantly increasing structural complexity.
Solution Approach 2:
The outer jacket is applied in advance to protect the fiber wire core before the conveying wire is put into service. This preliminary protective measure prevents damage from particulate minerals and moisture ingress that would otherwise cause breakage and mold formation, extending the service life of the conveying wire.
3Stability of the object's composition
If the fiber wire is kept tight during unwinding and conveying wire tight during winding, then strand opening is prevented, but the processing complexity increases
Solution Approach 1:
The system employs dynamic tension control during the unwinding and winding processes. By actively adjusting and maintaining appropriate tension levels on the fiber wire and conveying wire, the strands remain closed and stable without requiring overly complex processing equipment. The dynamic adjustment of tension prevents strand opening while keeping the process manageable.
4Reliability
If annular beads or soft thermoplastic elastomers are used for connection, then adhesion and flexibility are enhanced, but the manufacturing complexity increases
Solution Approach 1:
The outer jacket sections utilize changes in material parameters, specifically incorporating annular beads or soft thermoplastic elastomers at the opposing end parts. These parameter changes in the material structure enhance adhesion strength and flexibility. The beads or elastomeric regions are integrated into the injection molding process, allowing for enhanced performance without substantially increasing manufacturing complexity.
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 ensures a strong, permanent attachment of the outer jacket to the fiber wire and disc-shaped members, preventing damage and moisture ingress, while maintaining flexibility and hygiene, thus improving the durability and performance of the conveying wire in tube conveyor systems.
Implementation Method 1
connecting disc-shaped conveying members by injection moulding directly onto the at least one section of the outer jacket or directly onto the conveying wire
Implementation Method 2
ensures a strong, permanent attachment of the outer jacket to the fiber wire and disc-shaped members
Data Source
AI summary
A method of production of a conveying wire that includes a fiber wire with disc-shaped conveying members, the fiber wire including twisted strands each made from synthetic plastic threads or fibers, includes coating at least one section of the fiber wire with an outer jacket by a continuous injection molding process and connecting disc-shaped conveying members by injection molding directly onto the at least one section of the outer jacket or directly onto the fiber wire, and connecting opposed end parts of each section of the outer jacket to opposed end parts of disc-shaped conveying members, while maintaining the fiber wire under tension during unwinding and during winding.