Spray-On Wire Lubrication Enclosure for Clean Low-Friction Pulling
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Solution Overview
Problem
The installation of wires and cables is hindered by high friction, requiring excessive pulling force, and existing methods for reducing friction are inefficient, messy, and affect the aesthetic quality of the final product.
Innovation Solution
A system and method for spraying a lubricant onto the wire or cable during manufacturing, using an enclosure with adjustable nozzles to apply a fine mist and a drying chamber to prevent excess lubricant dispersal, reducing friction and pulling force during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If manual lubricating techniques are used to reduce friction during wire installation, then the coefficient of friction is reduced, but the manufacturing process becomes messy and time-consuming
Solution Approach 1:
The patent replaces manual mechanical lubrication methods with an automated spray system that uses compressed air to atomize and apply lubricant. This substitution eliminates the mess and time consumption associated with manual application while achieving the same friction reduction effect during wire installation
Solution Approach 2:
The spray system is integrated into the wire manufacturing process itself, allowing the lubricant to be applied automatically as the wire passes through the enclosure. The system serves itself by using the manufacturing line's movement to facilitate lubricant application without requiring separate manual intervention
2Force
If lubricant is incorporated into the outer jacket material, then friction is reduced during installation, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The patent extracts the lubricant application step from the complex process of incorporating lubricant into the outer jacket material. By separating these functions, the patent achieves friction reduction through a simple spray application rather than requiring complex mixing and extrusion process modifications
Solution Approach 2:
The lubricant is applied to the wire surface before installation in a preliminary spray action. This preliminary application is sufficient to reduce friction during installation without requiring the more complex and expensive approach of incorporating lubricant into the jacket material itself
3Force
If spray-on lubricant is applied without enclosure, then friction is reduced, but excess lubricant disperses creating safety and efficiency issues
Solution Approach 1:
The patent uses an enclosure with walls and seals to contain the spray environment. This enclosure acts as a barrier that prevents lubricant mist from dispersing into the manufacturing area while allowing the wire to pass through, thus eliminating safety and efficiency issues associated with unenclosed spray application
Solution Approach 2:
The enclosure creates a controlled environment where the lubricant spray is contained. By isolating the spray process within the enclosure, the patent prevents harmful lubricant dispersal into the surrounding manufacturing area while maintaining the friction reduction benefits
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 lubricant application reduces the coefficient of friction and pulling force required during installation, maintaining a clean and efficient manufacturing environment while allowing for the reuse or recycling of excess lubricant.
Implementation Method 1
The air system provides air to aerosolize the lubricant into a mist and to power the lubricant pump system
Implementation Method 2
The wire then enters the drying chamber where air dries the excess moisture from the spray-on lubricant dispersed upon the wire or cable. Excess dispersant is evaporated
Implementation Method 3
spray-on application of a pulling lubricant to a wire or cable, causing a reduced coefficient of friction and reduced pulling force to aid in the installation of wire or cable
Data Source
AI summary
A system, method, and apparatus lubricating a wire or cable during manufacturing, wherein the wire is aligned with an entry to a spraying enclosure and passes through a first seal of the spraying enclosure. Lubricant is sprayed onto the wire inside of the spraying enclosure while the unapplied, but sprayed, lubricant is collected at the bottom of the spraying enclosure. The wire passes through a second seal of the spraying enclosure, is aligned, and exits from the spraying enclosure.