Intermittent Wire Embedding for Complex Geometries
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Solution Overview
Problem
Conventional wire embedding systems face difficulties in embedding wires into complex geometries, particularly with thicker wires, due to issues like dislodging previously embedded wires, bending forces causing deformation, and inability to maintain tension, leading to inconsistencies and damage to substrates.
Innovation Solution
A wire embedding system utilizing a heating element and a wire positioning system that intermittently embeds wire at predetermined locations using heat and pressure, with the heating element and positioning system moved relative to the substrate between embedding instances to manage bending forces and maintain wire tension, and an edge press bar for precise positioning and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If continuous wire embedding systems are used on complex geometries, then wire embedding capability is achieved, but maneuvering difficulty increases and wire embedding consistency deteriorates
Solution Approach 1:
The wire embedding process is divided into discrete sequential embedding instances rather than continuous operation. The wire positioning system moves to predetermined locations and performs embedding at each location independently, allowing complex geometries to be accommodated through step-by-step positioning and embedding operations.
2Productivity
If continuous wire embedding is performed, then wire embedding efficiency is maintained, but bending forces cause wire deformation and previously embedded wires may be dislodged
Solution Approach 1:
The wire embedding system operates through periodic cycles of heating, pressing, and cooling at each predetermined location before moving to the next location. This periodic action allows the substrate to cool and set the embedded wire portion before the next embedding instance, preventing dislodgment and deformation while maintaining systematic progress through the embedding process.
3Device complexity
If wire embedding is performed without tension control, then system complexity is reduced, but wire positioning accuracy and embedding quality deteriorate
Solution Approach 1:
The wire positioning system applies tension to the wire before and during the embedding process at each location. This preliminary tensioning ensures the wire is properly positioned and taut before heating and pressing, improving embedding quality without requiring complex real-time tension control mechanisms during the actual embedding action.
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 system effectively embeds wires in complex geometries with thicker wires, reducing the risk of dislodgment and deformation, while maintaining accurate positioning and stability, enabling the creation of complex shapes and patterns.
Implementation Method 1
A wire is embedded in a substrate at predetermined locations in a series of sequential embedding instances using heat and pressure
Implementation Method 2
A wire is embedded in a substrate at predetermined locations in a series of sequential embedding instances using heat and pressure
Data Source
AI summary
A wire embedding system and methods are presented. A wire is embedded in a substrate at predetermined locations in a series of sequential embedding instances using heat and pressure. The heat and pressure are removed from the wire in between the series of sequential embedding instances.