Wound Wire Filter Joining Structure to Prevent Snagging
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Solution Overview
Problem
The welded parts on the outer surface of wound-type filters can catch on other components during handling, potentially damaging the filter or other parts.
Innovation Solution
A filter with a hollow cylindrical shape is formed by winding metal wires in a helical and multilayered manner, with deformed joining parts that include pressed and deformed metal wire portions joined by resistance spot welding, ensuring these joining parts penetrate into an inner communication space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If metal wires are wound in a helical and multilayered manner to form a filter, then the filter structure is formed, but the welded parts on the outer surface can catch on other components during handling
Solution Approach 1:
The joining part is designed to extend in the radial direction (another dimension) from the outer surface toward the inner communication space. This dimensional change moves the joining part from a surface-level feature to a three-dimensional structure that penetrates into the filter's internal space, effectively removing it from the problematic outer surface location where it could catch on components during handling.
2Strength
If welded parts are formed on the outer surface for joining metal wires, then the metal wires are joined, but the welded parts may damage the filter or other portions due to catching on components
Solution Approach 1:
The joining function is extracted from the outer surface location and relocated to the inner communication space. By forming the joining part radially inward from the outer surface, the harmful aspect (protruding welded part on the surface) is removed while the useful function (joining metal wires) is preserved in a new location that does not cause damage during handling.
3Ease of manufacture
If metal wire portions are pressed and deformed via resistance spot welding, then the metal wires are joined, but the joining part may protrude outward and catch on components
Solution Approach 1:
The joining part orientation is changed from a conventional outward-protruding configuration to a radially-inward extending configuration. This dimensional reorientation directs the joining part toward the inner communication space rather than outward, eliminating the handling problem while maintaining the resistance spot welding manufacturing process.
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 design reduces the likelihood of the joined metal wire portions catching on other components during handling, thereby minimizing damage and improving handleability.
Implementation Method 1
joined to the first metal wire portion by resistance spot welding
Data Source
AI summary
An object of the present invention is to make a joined portion of a metal wire less likely to catch on other components and the like. A hollow cylindrical filter 200 is formed by winding one or a plurality of metal wires 220 in a helical and multilayered manner so that metal wire portions adjacent to each other in a direction toward an inner or outer diameter side extend in directions crossing each other. The filter includes a deformed joining part 231 including a first metal wire portion 220A having been pressed and deformed and a second metal wire portion 220B having been pressed and deformed via the first metal wire portion and joined to the first metal wire portion by resistance spot welding, where the deformed joining part penetrates into a communication space positioned at an inner side of the deformed joining part. Since the metal wire is pressed and deformed at the deformed joining part, the deformed joining part is less likely to catch on other components and the like during handling of the filter.