Tungsten Wire Straightness and Strength via Grain Control
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Solution Overview
Problem
Conventional tungsten wires with small diameters experience a decrease in straightness while maintaining high tensile strength, making it challenging to achieve both properties simultaneously.
Innovation Solution
A tungsten or tungsten alloy metal wire with a diameter of at most 13 μm and a tensile strength of at least 4.8 GPa, manufactured using a process that includes swaging, heat drawing, drawing at room temperature, and low-temperature hot drawing to achieve high straightness and tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the diameter of tungsten wire is reduced to achieve small diameter requirements, then the wire can be used in applications requiring fine mesh structures, but the straightness of the wire deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the crystal grain size to be 10 μm or less through specific manufacturing processes. This parameter control enables the wire to maintain high straightness even at small diameters of 13 μm or less, resolving the contradiction between reduced diameter and maintained straightness.
2Volume of moving object
If the diameter of tungsten wire is reduced to achieve small diameter requirements, then the wire can be used in applications requiring fine mesh structures, but the tensile strength deteriorates
Solution Approach 1:
The patent controls the crystal grain size parameter to be 10 μm or less, which enables the wire to maintain high tensile strength of 4.8 GPa or more even at small diameters. This parameter control resolves the contradiction between reduced diameter and maintained tensile strength.
3Strength
If conventional manufacturing processes are used to maintain high tensile strength, then the wire strength is preserved, but the straightness decreases
Solution Approach 1:
The patent introduces a specific crystal grain size parameter control (10 μm or less) that simultaneously improves both tensile strength and straightness, breaking the conventional trade-off where high strength resulted in poor straightness.
4Area of stationary object
If the diameter is reduced to increase aperture ratio in mesh applications, then the mesh performance improves, but the wire becomes more prone to breakage
Solution Approach 1:
By controlling the crystal grain size to 10 μm or less, the patent enables the use of wires with diameter of 13 μm or less while maintaining high tensile strength of 4.8 GPa or more. This allows increased aperture ratio in mesh applications without compromising wire breakage resistance.
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 enables the production of metal wires with excellent tensile strength and straightness, suitable for applications like screen printing, where a high aperture ratio and precision are required, while maintaining workability and reducing wire breakage.
Implementation Method 1
a method of manufacturing a metal wire includes swaging
Implementation Method 2
heat drawing
Implementation Method 3
drawing at room temperature
Implementation Method 4
low-temperature hot drawing
Data Source
AI summary
A metal wire includes tungsten or a tungsten alloy. The metal wire has a diameter of at most 13 μm, a tensile strength of at least 4.8 GPa, and a natural hanging length per 1000 mm of at least 800 mm.