Diamond Wire Sheath Reinforcement at Cable Discontinuity Points
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Solution Overview
Problem
Current diamond wires for cutting stone-like materials face issues with structural integrity due to the limited containment capacity of heat-shrinkable sleeves, leading to unraveling and mechanical weakness at the discontinuity points of the multi-strand metal cable, which increases assembly time and costs.
Innovation Solution
A diamond wire production method involving a multi-strand metal cable with discontinuity points covered by an injection-molded thermoplastic sheath that includes enlarged segments over these points, providing enhanced mechanical resistance and preventing unraveling by embedding the cable ends within the sheath.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If heat-shrinkable sleeves are used to cover discontinuity points, then assembly time is reduced, but containment capacity is limited leading to cable unraveling
Solution Approach 1:
The patent changes the material parameter from heat-shrinkable material to injection-molded thermoplastic material, which provides superior containment capacity while maintaining assembly efficiency through automated injection molding processes
Solution Approach 2:
The patent uses composite material construction where thermoplastic material is injected to form a sheath that combines structural support and containment functions, creating a more reliable composite structure at the discontinuity points
2Reliability
If protective sleeves are positioned on metal cable, then strand ends are protected from detachment, but assembly time and costs increase significantly
Solution Approach 1:
The patent merges the protective function with the sheath formation process by injecting thermoplastic material that simultaneously protects strand ends and forms the outer sheath structure, eliminating the need for separate protective sleeve components and reducing assembly steps
Solution Approach 2:
The patent performs preliminary action by injecting the thermoplastic material to form enlarged segments at discontinuity points during the sheath formation process itself, preparing the protective structure in advance rather than adding it as a separate post-processing step
3Adaptability or versatility
If multi-strand metal cable is used, then mechanical flexibility is improved, but discontinuity points create weak spots reducing overall strength
Solution Approach 1:
The patent applies local quality by creating enlarged segments of thermoplastic sheath specifically at the discontinuity points where strand ends are exposed, providing localized reinforcement exactly where mechanical weakness occurs while maintaining the overall flexibility of the multi-strand cable structure
Solution Approach 2:
The patent provides beforehand cushioning by forming enlarged sheath segments at discontinuity points that act as protective cushions or reinforcement zones, preventing mechanical failure at weak spots before they can cause cable unraveling or failure during use
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
The method significantly increases the mechanical resistance to traction and bending, reducing the risk of unraveling and extending the lifespan of the diamond wire by at least 75% compared to traditional methods.
Implementation Method 1
forming the outer sheath directly over the metal cable via injection moulding
Implementation Method 2
the areas of the metal cable where the ends of the strands reciprocally butt are covered by tubes made of heat-shrinkable material
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A production method of a diamond wire (1) for cutting stone-like material comprising the steps of: threading a predetermined number of abrasive beads (3) on the supporting cable (2); joining the two ends (2a) of the supporting cable (2) by appropriately interweaving the strands (6) of the supporting cable (2), so as to form a closed loop; distributing the diamond beads (3) on the supporting cable (2) so that the discontinuity points (P) of the supporting cable (2) are arranged along as many uncovered longitudinal stretches (5) of the supporting cable (2) spaced from two abrasive beads (3) delimiting the same uncovered longitudinal stretch (5); and injection moulding the outer tubular sheath (4) made of plastic material directly over the supporting cable (2) so as to cover the supporting cable (2) and also form, at least along the uncovered longitudinal stretches (5) accommodating the discontinuity point (P) of the supporting cable (2), as many enlarged sheath segments (10) each extending astride the discontinuity point (P) and being spaced/distanced from the two abrasive beads (3) located at two ends of the same uncovered longitudinal stretch (5).