Toothed Cable Strand Joining via Meltable Filament Thread
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Solution Overview
Problem
Existing toothed cables face issues with flexibility due to excessive adhesion or uneven adhesive application, which affects the secure joining of the braid to the core cable, leading to potential wear and breakage when engaged with gears.
Innovation Solution
A toothed cable design featuring a core cable with a spirally disposed wire and a strand with piles, where a meltable filament thread is used to securely join the strand to the core cable by melting and solidifying it within a groove, maintaining flexibility by controlling the melting point and tension during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the core cable and wire are heated to a temperature higher than the melting point of the braid to melt the braid in contact with the wire, then the braid adheres to the core cable and wire, but the adhesion area increases and lengths of piles are shortened, deteriorating flexibility of the braid
Solution Approach 1:
The patent changes the temperature parameter by heating the core cable and wire to a temperature range of 80°C to 120°C, which is above the glass transition temperature of the braid material but controlled to prevent excessive melting. This parameter optimization ensures adequate adhesion while preserving braid flexibility and pile length
Solution Approach 2:
The patent utilizes the phase transition of the braid material from solid to softened state during heating, allowing the braid to adhere to the core cable and wire. The controlled heating causes the thermoplastic braid material to transition to a pliable state for bonding, then cool to regain structural integrity while maintaining flexibility
2Strength
If adhesive is applied to the core cable to fix the braid, then the braid is joined to the core cable, but if the amount of adhesive is large, flexibility of the braid deteriorates because adhesive enters between piles and solidifies
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive) with a thermal bonding method. By heating the core cable and wire to an appropriate temperature range, the braid material undergoes phase transition and adheres through thermal fusion rather than chemical adhesive bonding. This eliminates the problem of adhesive penetrating and solidifying between piles, preserving braid flexibility while achieving secure joining
3Ease of operation
If adhesive is applied to the core cable to fix the braid, then the braid is joined to the core cable, but if the amount of adhesive is small, it is difficult to adjust application amount and joining may be off due to uneven application
Solution Approach 1:
The patent replaces the manual adhesive application process with a thermal heating process. The heating device uniformly heats the core cable and wire to a controlled temperature range (80°C to 120°C), ensuring consistent thermal bonding across the entire braid contact area. This eliminates the variability and control difficulties associated with manual adhesive application while ensuring reliable and uniform joining
Solution Approach 2:
The thermal heating process enables the braid to self-adhere to the core cable and wire through phase transition of its own material structure. The braid material itself provides the bonding mechanism through thermal softening and cooling, eliminating the need for external adhesive application and its associated control issues
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 ensures a secure and flexible connection between the core cable and the strand, preventing wear and breakage during gear engagement while maintaining the cable's flexibility and reducing noise from sliding.
Implementation Method 1
a filament thread melting step of melting the filament thread after the strand is disposed
Implementation Method 2
a joining step of joining the strand to the core cable by solidifying the melted filament thread
Data Source
AI summary
A toothed cable is provided in which a strand can be securely joined to a core cable while maintaining flexibility of the strand. The toothed cable includes the core cable, a wire disposed spirally around the core cable at a fixed pitch, and the strand having a core thread and piles fixed to the core thread, the strand being disposed spirally along a groove having side walls and a bottom formed by the wire and the core cable. The toothed cable is obtained by a manufacturing method of disposing a meltable filament thread in the groove, disposing the strand in the groove with tension after the filament thread is disposed, melting the filament thread after the strand is disposed, and joining the strand to the core cable by solidifying the melted filament thread.