Individually Sheathed Strand With Alternating Adhesion Zones
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Solution Overview
Problem
Existing methods for producing individually sheathed strands with alternating adhesive and non-adhesive portions are costly, difficult to implement, and result in incomplete adhesion due to residual wax, leading to discontinuities and reduced mechanical performance.
Innovation Solution
A method involving selective application of two filler products - one adhesive and one lubricating - followed by extrusion of a continuous plastic sheath, ensuring controlled industrial production of strands with alternating adhesive and non-adhesive portions without interference with adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a filler product is applied to create adhesion between sheath and metal wires, then mechanical integrity is improved, but manufacturing complexity increases due to difficulty in controlling adhesion in specific portions only
Solution Approach 1:
The patent applies local quality by using two distinct filler products with different adhesion characteristics in different portions of the strand. The first filler product provides adhesion in portions where mechanical integrity is required, while the second filler product provides lubrication in portions where flexibility is needed. This local differentiation resolves the contradiction by enabling controlled adhesion application without requiring complex manufacturing processes.
2Strength
If resin is applied to create coherent adhesion portions, then mechanical strength is improved, but manufacturing cost increases and adhesion is compromised by residual wax
Solution Approach 1:
The patent applies preliminary action by removing wax from specific portions of the strand before applying the resin filler product. This preparatory step ensures that the resin can achieve proper adhesion to the metal wires without interference from residual wax. By performing this preliminary wax removal, the method avoids the need for costly and complex degreasing processes while ensuring reliable adhesion in the coherent portions.
3Adaptability or versatility
If alternating adhesive and non-adhesive portions are created, then versatility is improved, but manufacturing precision deteriorates due to discontinuities in the sheath
Solution Approach 1:
The patent resolves the contradiction between versatility and manufacturing precision by applying local quality through selective filler product application. The continuous sheath is maintained throughout the strand, while the internal filler products are selectively applied to create alternating adhesive and non-adhesive portions. This approach preserves sheath continuity and manufacturing precision while achieving the desired functional versatility.
4Duration of action of stationary object
If lubricating filler product is used, then fatigue behavior is improved, but adhesion capability deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the strand into alternating portions with different filler product characteristics. Lubricating portions with fatigue-resistant properties are alternated with adhesive portions that provide strong bonding. This segmentation allows the strand to exhibit both fatigue resistance and adhesion capability in different sections, resolving the contradiction between these two opposing requirements.
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
Ensures reliable, uninterrupted protection and mechanical integrity by maintaining adhesion in required portions while reducing costs through controlled application of filler products and continuous sheathing.
Implementation Method 1
the filler product is a lubricant, which in particular has the advantage of improving the fatigue behavior of the strand by lubricating the contacts between its metal wires
Implementation Method 2
the second filler product having greater adhesion to the group of metal wires than the first filler product
Implementation Method 3
extruding a plastic material around the group of metal wires passing through the die, so as to envelop the group of metal wires coated with the first and second filler products in a continuous sheath formed of the extruded plastic material
Data Source
AI summary
The method for manufacturing an individually sheathed strand comprises: conveying a group of metal wires through a die; upstream of the die, applying a first filler product to at least a first portion of the strand; upstream of the die, applying a second filler product to at least a second portion of the strand distinct from the first portion; and extruding a plastic around the group of metal wires passing through the die, so as to envelop the group of metal wires covered with the first and second filler products in a continuous sheath formed of the extruded plastic. The second filler product has greater adhesion to the group of metal wires than the first filler product.