Discrete-Step Braiding Mechanism for Fine-Filament Tubular Braids
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Solution Overview
Problem
Existing braiding machines are limited in producing high wire count tubular braids of small diameter filaments without breakage, particularly for medical applications requiring fine wires with low tensile strength.
Innovation Solution
The braiding apparatus includes a disc with a circumferential edge and a mandrel, featuring catch mechanisms and actuators that move filaments radially and interweave them in discrete steps, reducing tension spikes and preventing filament breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional maypole-type braiding machines are used to braid fine filaments, then the braiding process can be performed, but the filaments break due to high tension and radial movement
Solution Approach 1:
The braiding mechanism divides the filament handling into discrete segments: filaments are individually engaged by catch mechanisms, moved in controlled radial steps, and released at specific positions. This segmentation allows tension to be applied only during controlled engagement phases rather than continuously, preventing filament breakage while maintaining braiding functionality.
Solution Approach 2:
The mechanism employs periodic radial movement of the catch mechanisms - engaging filaments at one radial position, moving them to another position, and releasing them. This periodic action pattern creates controlled tension cycles that prevent continuous stress accumulation on fine filaments, thereby improving reliability without requiring excessive force.
2Productivity
If high-speed braiding is attempted with fine filaments, then productivity increases, but filament breakage increases due to tension spikes
Solution Approach 1:
The catch mechanisms preliminarily engage and position filaments at controlled radial distances before the actual braiding action. This preliminary positioning allows the system to prepare fine filaments in advance, reducing sudden tension spikes during high-speed operation while maintaining productivity through efficient pre-positioning and controlled movement phases.
Solution Approach 2:
The catch mechanisms serve as intermediaries between the drive system and the filaments. These intermediaries absorb and distribute tension forces, allowing high-speed operation to proceed without direct transmission of tension spikes to the fine filaments. The catch mechanisms mediate the interaction, protecting filament integrity while enabling productive braiding speeds.
3Reliability
If discrete step braiding is used instead of continuous motion, then tension spikes are reduced, but the braiding process becomes more complex
Solution Approach 1:
The catch mechanisms perform multiple functions: they engage filaments, control radial movement, position filaments for braiding, and release them. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing device complexity while achieving reliable discrete-step braiding that protects filament strength.
Solution Approach 2:
The mechanism dynamically adjusts the radial position of catch mechanisms based on the braiding requirements. The system transitions between different radial positions and engagement states as needed, allowing flexible control of tension during discrete steps. This dynamic adaptability manages complexity through programmed motion control rather than requiring complex mechanical structures for each fixed position.
Data Source
AI summary
Methods of braiding using a braiding mechanism are described. The braiding mechanism includes a disc defining a plane and a circumferential edge, a mandrel extending from a center of the disc that is adapted to hold a plurality of filaments extending radially from the mandrel toward the circumferential edge of the disc, a plurality of catch mechanisms positioned circumferentially around the edge of the disc, a plurality of actuators adapted to move the plurality of catch mechanisms in a substantially radial direction relative to the circumferential edge of the disc, and a plurality of filaments extending radially from the mandrel towards circumferential edge of the disc. A middle portion of each filament of the plurality of filaments contacts an end of the mandrel.