Induction Heating for Modular Leash Bonding
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Solution Overview
Problem
Existing modular leash manufacturing methods lack efficient and cost-effective processes for integrating flexible and handle portions, limiting the versatility and aesthetics of modular leashes.
Innovation Solution
The method involves heating pins or sleeves using induction heating to melt and secure flexible materials, creating a strong bond between components, allowing for the assembly of modular leashes with various materials like ropes, chains, and webbing, and incorporating adjustable fittings for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional manufacturing methods are used to assemble modular leash components, then the manufacturing process is simple, but the bond strength and durability between components is insufficient
Solution Approach 1:
The patent applies heating to change the physical state of the flexible material, transforming it from a solid to a molten state to enable bonding. This parameter change (temperature) allows the material to flow and adhere to metal components, creating a strong bond without complex assembly procedures.
Solution Approach 2:
The patent utilizes the phase transition of the flexible material from solid to liquid through heating. This phase transition enables the material to penetrate and bond with metal components like pins and sleeves, achieving strong structural attachment while maintaining manufacturing simplicity.
2Adaptability or versatility
If modular leash components are manufactured separately for customization, then versatility and aesthetics are improved, but manufacturing efficiency and cost-effectiveness decrease
Solution Approach 1:
The patent divides the leash into separate modular components (flexible portion, metal components, fittings) that can be manufactured independently. This segmentation enables customization of different parts while maintaining efficient, specialized manufacturing processes for each component type.
Solution Approach 2:
The patent combines separately manufactured components through a simplified heating and bonding process. This merging approach allows customized components to be assembled efficiently, maintaining both versatility and manufacturing productivity by avoiding complex integrated manufacturing.
3Strength
If heating is used to bond flexible material to metal components, then bond strength is improved, but energy consumption increases
Solution Approach 1:
The patent replaces mechanical bonding methods (screws, rivets, adhesives) with thermal bonding. This substitution achieves superior bond strength through localized heating that melts and fuses the flexible material to metal components, eliminating the need for additional mechanical fasteners or chemical adhesives.
Solution Approach 2:
The flexible material itself serves as the bonding agent through its own thermal response. When heated, the material naturally melts and adheres to the metal components, using its inherent properties rather than requiring external bonding agents or complex fastening mechanisms.
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 enables the cost-effective and aesthetically pleasing manufacturing of modular leashes with improved durability and versatility, allowing for easy customization and attachment of accessories, enhancing their utility beyond pet control to include toddler leashes and key lanyards.
Implementation Method 1
heating the pin uses induction heating
Implementation Method 2
at least partially melt the lead to the pin using ambient heat from the heated pin
Implementation Method 3
at least partially melt the lead to the pin
Implementation Method 4
heating the sleeve uses induction heating
Implementation Method 5
at least partially melt the lead to the sleeve using ambient heat from the heated sleeve
Implementation Method 6
at least partially melt the lead to the sleeve
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Methods for manufacturing modular leashes are disclosed. The modular leashes may comprise a flexible portion including a lead end and a handle portion. Manufacturing the flexible portion may comprise heating a pin and securing the pin to a lead end, so as to melt the lead to the pin using ambient heat from the pin. In some embodiments, heating the pin uses induction heating. Manufacturing the flexible portion may further comprise inserting the lead end into a sleeve, and securing the lead to the sleeve by crimping the sleeve onto the lead. Manufacturing the handle portion may comprise inserting handle ends into a first end of a sleeve and inserting a fastener into the handle ends. Manufacturing the handle portion may further comprise inserting a fitting into a second end of the sleeve so that a space between the sleeve and the fitting may receive the handle ends.