Polymer-Anchored Torque Coil Assembly Without Heat Joining
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Solution Overview
Problem
Existing helically-wound torque coils secured with solder or brazing face limitations, particularly in applications where heat application can damage polymer cores, and there is a need for a method to assemble coils without damaging them.
Innovation Solution
A torque coil design featuring an inner and outer wire layer secured by a polymer core and outer polymer cover, eliminating the need for welding, brazing, or soldering, with controlled polymer penetration between wire layers to achieve variable stiffness and flexibility, and a method involving helical winding and polymer coating to prevent unwinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solder or brazing is used to secure wire layers, then the coil structure is stabilized, but the polymer core is damaged due to heat application
Solution Approach 1:
The patent replaces thermal joining methods (soldering, brazing) with a mechanical anchoring system where wire ends are inserted into and mechanically secured within the polymer core. This mechanical substitution eliminates heat application entirely, stabilizing the coil structure without damaging the polymer core material.
Solution Approach 2:
The patent introduces the polymer core as an intermediary element that serves dual functions: it provides mechanical anchoring for the wire ends to prevent uncoiling, and it protects itself from heat damage by eliminating the need for thermal joining processes. The core acts as both the securing mechanism and the protected component.
2Strength
If wire layers are tightly wound to prevent uncoiling, then structural integrity is improved, but flexibility and ability to withstand compression are reduced
Solution Approach 1:
The patent divides the coil into multiple wire layers (inner and outer layers) that are independently wound and then secured at their ends to the polymer core. This segmentation allows each layer to contribute to structural integrity while the overall multi-layer construction provides flexibility and compression resistance that a single tightly-wound layer cannot achieve.
Solution Approach 2:
The patent creates a composite structure combining multiple wire layers with a polymer core. The wire layers provide structural integrity and torque transmission, while the polymer core provides flexibility and compression resistance. The composite nature of this assembly resolves the contradiction between strength and adaptability.
3Strength
If complex assembly methods like welding or brazing are used, then connection strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces complex thermal joining processes (welding, brazing) with a simple mechanical insertion method where wire ends are placed into the polymer core. This mechanical system provides sufficient connection strength for the application while dramatically simplifying the manufacturing process and reducing assembly time.
Solution Approach 2:
The polymer core serves as both the structural element and the anchoring mechanism. The wire ends are simply inserted into the core, which inherently secures them through its physical structure without requiring additional joining steps. This self-service approach eliminates complex assembly procedures while maintaining connection strength.
Data Source
AI summary
A torque coil 10 includes an inner wire layer 14 helically wound in a constricted state. An outer wire layer 18 is helically wound over the inner wire layer in a constricted state. An outer polymer cover 20 surrounds the inner and outer layers thereby securing the inner and outer layers within the outer polymer cover.