Steel Cord Connection Fixation Section
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Solution Overview
Problem
Existing connections for steel cords, such as welds, often lead to 'filament breaking' issues due to structural changes in the metallurgy, causing brittleness and failure during handling and processing, especially in open cords where filaments can sleeve and break at the weld, resulting in process stops and material loss.
Innovation Solution
A connection method involving a jointed section with a separate fixation section, where filaments are immobilized by soldering or brazing, preventing radial and longitudinal movement, thus isolating potential overlength accumulation and preventing filament breakage by ensuring overlength is managed before reaching the jointed area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a weld is used to connect steel cord ends, then the connection strength is improved, but filament breakage occurs due to metallurgical structure changes
Solution Approach 1:
The connection is divided into two distinct sections: a jointed section for connecting cord ends and a fixation section for immobilizing filaments. This segmentation allows the weld to provide strength while the fixation section prevents filament breakage by restraining filament movement away from the brittle weld zone.
Solution Approach 2:
The fixation section acts as an intermediary between the weld and the rest of the cord. It provides a transition zone where filaments are immobilized, preventing them from moving into the brittle weld area where they would otherwise break under stress.
2Productivity
If the cord length is increased to reduce downtime, then productivity is improved, but the risk of connection failure increases
Solution Approach 1:
The fixation section is positioned beforehand to cushion against potential filament breakage at the weld. By immobilizing filaments in advance before they reach the weld zone, the design pre-prevents the failure mode that would otherwise occur during high-speed processing of long cords.
3Adaptability or versatility
If open cord structure is used for flexibility, then adaptability is improved, but filament sleeving and breakage at weld increases
Solution Approach 1:
The open cord structure is maintained in most areas for flexibility, but the fixation section introduces a localized change where filaments are immobilized. This local quality change prevents sleeving and breakage at the weld while preserving the overall flexibility and adaptability of the cord in non-fixation areas.
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 solution effectively prevents filament breakage by isolating overlength accumulation in the fixation section, maintaining the metallurgical structure of the steel and ensuring the connection withstands processing without interruptions, significantly reducing downtime and material loss.
Implementation Method 1
By soldering or brazing, the filaments are fixed to one another in a fixation section
Implementation Method 2
By soldering or brazing, the filaments are fixed to one another in a fixation section
Data Source
Figure 1~2
AI summary
A connection for connecting steel cord ends to one another is described. The connection solves the problem of filaments that break off at the connection during handling of the cord. In the inventive connection a fixation section is introduced before or after the jointing section. The fixation section immobilises the filaments relative to one another. A method to make such a connection is also described. The connection and the method turn out to be extremely useful for connecting steel cords of the open type.