Spliced Fiber-Reinforced Filtration Shell Bonding
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Solution Overview
Problem
Conventional splicing techniques for fiber-reinforced filtration elements result in enlarged or weak fiber unions, which are unsuitable for applications requiring close tolerances and are particularly challenging for stranded fibers, especially in large-scale manufacturing environments.
Innovation Solution
A method involving aligning the ends of multi-strand fibers along a common axis, wrapping a thin heat-shrinkable film with adhesive around the aligned ends, and heating it to form an integral bond, ensuring a uniform and strong spliced fiber with minimal cross-sectional area variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional splicing techniques (knots, shrink wrap tubing sleeves) are used to join fiber ends, then the fibers can be connected, but the union becomes enlarged which is unacceptable for applications requiring close tolerances
Solution Approach 1:
The patent replaces mechanical splicing methods (knots, physical sleeves) with a thermal bonding process. Heat-shrinkable tubing with adhesive is heated to melt and bond the fiber strands together, creating a uniform union without mechanical enlargement. This thermal-chemical bonding substitution resolves the contradiction by achieving reliable connection without tolerance violation.
Solution Approach 2:
The patent changes the physical state parameters of the bonding material from solid to molten and back to solid through controlled heating and cooling. The adhesive transitions from solid (in tubing) to liquid (when heated) to bond fibers, then re-solidifies to form a strong union. This parameter change enables uniform bonding without enlargement, resolving the precision-reliability contradiction.
2Reliability
If heat shrinkable tubing sleeves are used for splicing, then fiber connection is achieved, but insertion within tubing sleeve is extremely difficult for stranded fibers in large scale manufacturing
Solution Approach 1:
The heat-shrinkable tubing performs self-alignment and self-bonding functions. When heated, the tubing automatically shrinks onto the fiber strands and the adhesive melts to bond them together without requiring precise manual positioning or complex insertion tools. The stranded fiber structure feeds into the open tubing easily, and the thermal process completes the bonding automatically, resolving the manufacturing ease contradiction.
Solution Approach 2:
The patent utilizes phase transition of the adhesive from solid to liquid and back to solid. The adhesive is solid during handling and insertion, then melts to liquid when heated to enable bonding, and re-solidifies to create the strong union. This phase transition sequence simplifies the manufacturing process by providing clear operational stages without requiring difficult precision insertion, resolving the ease of manufacture issue.
3Ease of manufacture
If butt-end adhesive is used for fiber splicing, then the process is simple, but the spliced fiber lacks sufficient strength and flexibility
Solution Approach 1:
The patent uses a composite bonding system combining heat-shrinkable tubing material and adhesive material working together. The tubing provides structural containment and thermal transmission, while the adhesive provides bonding strength. This composite approach maintains process simplicity while achieving superior union strength and flexibility compared to simple butt-end adhesive, resolving the strength-simplicity contradiction.
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 method produces a spliced fiber with consistent cross-sectional area, providing adequate strength and flexibility, suitable for applications requiring close tolerances and scalable manufacturing, while avoiding the limitations of conventional splicing techniques.
Implementation Method 1
heating the film so that the film draws inward upon the aligned ends of each fiber
Implementation Method 2
heat-shrinkable film includes a layer of adhesive that contacts the overlapping strands of the fibers
Data Source
AI summary
A filtration element with a fiber-reinforced shell and a method for fabricating the same. The fabrication method including the steps of: i) coating a multi-strand fiber with a liquid resin, ii) winding the coated fiber about the cylindrical filtration element, and iii) solidifying the resin to form a fiber-reinforced shell. The method is characterized by utilizing a spliced fiber formed by: a) aligning an end of a first multi-strand fiber with an end of a second multi-stand fiber such that the aligned fibers extend along a common axis (X), b) wrapping a layer of a heat-shrinkable film about the outer diameter of the aligned ends of the fibers wherein heat-shrinkable film includes a layer of adhesive that contacts the overlapping strands of the fibers, and c) heating the film so that the film draws inward upon the aligned ends of each fiber and forms an integral bond such that the effective cross-sectional area of a section of fiber.