Helical Coil Production via Rotating Channel Heating
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Solution Overview
Problem
Existing methods for producing helical coils from plastic filaments face challenges in achieving efficient and gentle heating, leading to deformation issues and jamming during the winding process, especially when the filament is not rotationally symmetric.
Innovation Solution
A method involving a filament being conveyed through rotating channel portions with a heated fluid, followed by deformation just before winding onto a mandrel, ensuring continuous and efficient heating and deformation to achieve a stable helical coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the filament is deformed to a flattened cross-sectional area before winding, then the helical coil achieves better mechanical stability and shape retention, but the filament can tilt or jam in the guide elements during rotation
Solution Approach 1:
The filament is heated in advance before deformation, which softens the material and makes it more pliable. This preliminary heating action enables the filament to be deformed into a flattened cross-section without subsequent tilting or jamming during the winding process, as the softened material can better accommodate the guide elements.
Solution Approach 2:
The physical state of the filament is changed by heating it to a softened state before deformation. This parameter change (temperature increase) allows the filament to be deformed into a non-circular cross-section while maintaining reliability during winding, as the softened material is more compliant and less likely to jam in the guide elements.
2Stability of the object's composition
If the filament is heated before winding, then the wound filament retains the specified shaping permanently, but the heating must be precisely controlled to avoid deformation issues
Solution Approach 1:
A heating element acts as an intermediary between the heat source and the filament, providing controlled and uniform heating. This intermediary ensures that the filament reaches the appropriate temperature for shape retention without excessive heating that could cause deformation or material degradation, thereby reducing the precision requirements for direct heating control.
Solution Approach 2:
The heating process is applied continuously throughout the winding operation rather than as a separate discrete step. This continuous heating ensures that the filament maintains the appropriate temperature and pliability throughout the entire winding process, providing consistent shape retention without requiring precise timing or temperature control at specific moments.
3Shape
If the filament is deformed immediately after unwinding, then the cross-sectional area is changed, but the filament tilts outside or inside the channel portions during rotation
Solution Approach 1:
The filament is heated in advance before deformation, which softens the material and improves its rotational stability. This preliminary heating action ensures that when the filament is subsequently deformed and conveyed through rotating channel portions, it maintains sufficient pliability and stability to prevent tilting outside or inside the channels during rotation.
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 approach allows for quick, reliable, and disruption-free production of helical coils with improved mechanical stability and higher production speeds by ensuring uniform heating and deformation of the filament before winding.
Implementation Method 1
A heated heating fluid flows with an excess pressure through the first channel portion and the second channel portion, arranged downstream, and in the process heats the filament conveyed through the first channel portion and subsequently through the second channel portion.
Implementation Method 2
A heated heating fluid flows with an excess pressure through the first channel portion and the second channel portion, arranged downstream, and in the process heats the filament conveyed through the first channel portion and subsequently through the second channel portion.
Data Source
AI summary
In a method for producing helical coils, in particular for coil screens, a filament is conveyed in a filament conveying direction through a first channel portion of a first rotation body, and subsequently conveyed through a second channel portion of a second rotation body which rotates synchronously with the first rotation body. The filament is subsequently wound around a protruding winding mandrel, such that a helical coil is produced from the filament by a continuous feed of the windings of the filament wound around the winding mandrel. A heated heating fluid flows with an excess pressure through the first channel portion and the second channel portion, arranged downstream, and in the process heats the filament conveyed through the first channel portion and subsequently through the second channel portion. The filament emerging from the second channel portion is deformed, using a deformation apparatus, prior to winding onto the winding mandrel.