Fibre Coil Winding With Adhesive Droplets for Homogeneous Packing
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Solution Overview
Problem
Existing methods for producing fiber coils, such as winding fibers around a coil carrier and potting with a compound or applying adhesive layer by layer with a brush, result in non-homogeneous, non-compact coils due to displacement of fiber sections, high production costs, and manual intervention delays, leading to reliability and accuracy issues.
Innovation Solution
A winding device that uses an adhesive device to apply droplets of adhesive to the fiber coil, allowing for automatic, compact, and homogeneous winding by bonding fibers with droplets of adhesive applied to the outermost layer, which are then cured with UV or visible light, eliminating the need for manual handling and potting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If fibers are wound tightly to increase packing density, then coil compactness improves, but fiber displacement and non-homogeneous winding occur due to tension and compression forces
Solution Approach 1:
Adhesive droplets are applied to the fiber coil before the fiber winding process begins. This preliminary application of adhesive creates a bonding mechanism that will prevent fiber displacement during subsequent tight winding operations, allowing the coil to be wound compactly without sacrificing winding homogeneity.
Solution Approach 2:
Adhesive droplets serve as an intermediary substance between the fiber coil and the winding process. The adhesive mediates the interaction by providing bonding strength that counteracts the tension and compression forces generated during tight winding, thereby preventing fiber displacement while enabling compact coil formation.
2Strength
If adhesive is applied layer by layer with a brush to bond fiber sections, then fiber bonding improves, but mechanical contact causes fiber displacement and destroys homogeneous winding pattern
Solution Approach 1:
The mechanical brush application system is replaced with a droplet application system. Instead of using a brush that makes mechanical contact with the fiber coil, adhesive is applied in the form of droplets that are deposited onto the fiber coil. This substitution eliminates the mechanical contact that causes fiber displacement while maintaining the bonding function of the adhesive.
3Stability of the object's composition
If potting compound is used to fix the entire fiber coil, then fiber fixation improves, but potting compound penetration is insufficient and causes fiber displacement
Solution Approach 1:
The continuous potting compound application is segmented into discrete droplet applications. Instead of applying a continuous layer of potting compound that fails to penetrate properly, adhesive is applied in segmented droplet form at specific locations on the fiber coil. This segmentation allows for better penetration and distribution while providing effective fiber fixation without causing displacement.
4Ease of operation
If manual handling is used for potting mold transfer and coil removal, then process flexibility improves, but production time increases and fiber breaking risk occurs
Solution Approach 1:
The adhesive droplet application system is designed to be self-sufficient and integrated into the winding process. The adhesive is applied automatically during the winding operation itself, eliminating the need for separate manual potting mold transfer and coil removal steps. This self-service approach maintains process flexibility while dramatically improving production speed and reducing fiber breaking risk.
5Strength
If 2-component reactive adhesives are used, then bonding strength improves, but viscosity increase over time causes processing difficulties and equipment clogging
Solution Approach 1:
The adhesive system parameters are changed from 2-component reactive adhesives to single-component adhesives that do not exhibit significant viscosity increase over time. This parameter change maintains adequate bonding strength for fiber fixation while eliminating the viscosity-related processing difficulties and equipment clogging problems associated with 2-component systems.
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 solution enables fully automated production of compact and homogeneous fiber coils with improved reliability and reduced production time, avoiding mechanical contact and potential adhesive changes, while using adhesives that maintain consistent properties and reduce environmental contamination.
Implementation Method 1
an adhesive device (130) suitable for producing droplets of adhesive (140) and for applying the droplets of adhesive (140) onto the coil body (220) or the newly fed fiber (210) in order to bond the newly placed fiber (210) to fiber (210) already wound onto the coil body (220)
Implementation Method 2
a radiation source (160) emitting in the wavelength range of UV and/or visible light for irradiating the adhesive applied to and/or between the fiber (210) with light (165) in order to cure the adhesive (145)
Data Source
AI summary
The invention relates to a winding device (100) for winding a fibre coil, comprising a coil carrier (110) for wrapping with fibre (210) in order to produce a coil body (220) made of wound fibres (210), a fibre supply (120) for supplying a fibre (210) for wrapping the coil carrier (110), and an adhesive device (130) for producing droplets of adhesive (140) for bonding the outermost layer of fibres (210) on the coil body (220) to fibres (210) freshly laid onto the coil body (220).