Spiral Helix Wire Body Manufacturing Process
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Solution Overview
Problem
Conventional methods for producing shaped wire bodies are complex and wasteful, involving elaborate manufacturing processes for preliminary products like wire mesh, which result in metal waste and difficulty in achieving precise weight specifications.
Innovation Solution
A method where a conventional wire is preformed into a spiral-shaped helix structure and directly inserted into a forming device, eliminating the need for separate manufacturing steps, allowing for precise control over weight and flow properties by adjusting wire length and cross-sectional shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional wire mesh or wire woven fabrics are used as semi-finished products, then the wire body structure is complex and elaborate, but the manufacturing process becomes highly complex and generates large quantities of metal waste
Solution Approach 1:
The invention divides the manufacturing process into separate stages: first producing simple wire elements, then assembling them into the final wire body structure. This avoids the complexity of manufacturing elaborate wire mesh as a single continuous piece, reducing both process complexity and material waste.
Solution Approach 2:
Instead of starting with complex wire mesh and simplifying, the invention inverts the approach by building up the structure from simple wire elements through assembly. This reverse engineering approach simplifies the manufacturing process while achieving the same structural complexity in the final product.
2Length of moving object
If wire knits, wire meshes, or wire woven fabrics are cut to desired length, then the semi-finished products are ready for forming, but large quantities of metal waste are generated and manual cleaning is required
Solution Approach 1:
The invention performs preliminary actions by pre-forming simple wire elements before assembly, rather than cutting complex wire mesh. This allows precise length control at the element level, minimizing waste generation and eliminating the need for manual cleaning of cut remnants.
3Productivity
If wire material is oiled before knitting, weaving or crocheting, then the process runs smoothly, but additional processing steps and materials are required
Solution Approach 1:
The invention extracts and eliminates the oiling step from the manufacturing process by using a different formation method that does not require lubrication. This removes an unnecessary processing step and associated materials while maintaining productive assembly.
4Productivity
If continuous wire tubes or mats are produced, then mass production is enabled, but precise weight specification is hardly possible due to uncontrollable mesh cutting points
Solution Approach 1:
The invention segments the wire body into discrete elements with controlled weights, then assembles a precise number of these elements to achieve the desired total weight. This segmentation approach enables both mass production and precise weight specification, overcoming the limitation of continuous production methods.
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 simplifies the manufacturing process, reduces material usage by up to 60% while maintaining equivalent flow resistance and heat transfer capabilities, enabling precise weight and flow behavior adjustments.
Implementation Method 1
adjacent spiral sections of the wire are brought into engagement with each other and plastically deformed in such a way that a defined wire structure permeable to liquids and gases is retained after forming
Data Source
Figure 1~3
Figure 2a~2c
AI summary
The invention relates to a method for producing a formed wire body from at least one wire (16), the elongated wire being pre-formed in the shape of a spiral helical structure, the spiral pre-formed wire being then inserted into a forming device (18) to produce an intermediate product and the intermediate product being formed by the forming device to a formed wire body. The invention further relates to a formed wire body.