Fused Wires Diameter Control via Line Contact Heating
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Solution Overview
Problem
Existing methods for fusing insulated wires often result in significant deformation and overlap of insulation coatings, leading to a combined diameter of the fused wire that is less than 75% of the combined initial diameters of the individual wires, which is undesirable for applications requiring minimal space and precise wire routing.
Innovation Solution
A method where fully cured insulated wires are brought into close abutting contact along a line and then heated above the thermal transition point of at least one wire to fuse the coatings together, minimizing deformation and maintaining the original diameter of the fused wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heated insulation coatings are pressed together to fuse the wires, then the wires are bonded together, but the insulation coatings deform and overlap significantly
Solution Approach 1:
The wires are pre-aligned in a parallel configuration before heating, ensuring they are positioned correctly to maintain minimal contact during the fusion process. This preliminary positioning prevents deformation and overlap of the insulation coatings while still achieving strong bonding through the heating step.
2Strength
If insulation coatings are heated and pressed together, then the wires are fused, but the combined diameter becomes significantly smaller than the sum of individual diameters
Solution Approach 1:
The wires are pre-aligned in a parallel configuration before heating, ensuring they are positioned correctly to maintain minimal contact during the fusion process. This preliminary positioning prevents deformation and overlap of the insulation coatings while still achieving strong bonding through the heating step.
3Ease of manufacture
If wires are brought into close contact while insulation is heated and not fully cured, then the coatings fuse together, but it is difficult to avoid deforming the insulation coatings
Solution Approach 1:
The wires are pre-aligned in a parallel configuration before heating, ensuring they are positioned correctly to maintain minimal contact during the fusion process. This preliminary positioning prevents deformation and overlap of the insulation coatings while still achieving strong bonding through the heating step.
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 ensures a fused wire with a combined diameter that closely matches the sum of the individual wires' diameters, providing a strong bond while preserving the integrity and dimensions of the insulation coatings, suitable for applications like medical devices.
Implementation Method 1
heating device which heats the coatings above a thermal transition point of at least one of the pair of wires to fuse the coatings of the wires together
Data Source
AI summary
A method for fusing a pair of insulated wires to one another, and a fused wire made by such method, in which the combined or major diameter of the fused wire equals, or very closely matches, the sum of the diameters of the individual wires prior to fusion. In the present method, a pair of wires, each having a coating of insulation that is substantially fully cured, are brought into close abutting contact with one another along a line contact, and thereafter pass through a heating device which heats the coatings above their a thermal transition point of at least one of the pair of wires to fuse the coatings of the wires together along the line contact.