U.S. patent application number 12/428581 was filed with the patent office on 2010-10-28 for apparatus and method for forming a wave form for a stent from a wire.
This patent application is currently assigned to MEDTRONIC VASCULAR, INC.. Invention is credited to Michael Craven, Erik Griswold, Mark Hoff, Daniel Moore, Gianfranco Pellegrini.
Application Number | 20100269950 12/428581 |
Document ID | / |
Family ID | 42991058 |
Filed Date | 2010-10-28 |
United States Patent
Application |
20100269950 |
Kind Code |
A1 |
Hoff; Mark ; et al. |
October 28, 2010 |
Apparatus and Method for Forming a Wave Form for a Stent From a
Wire
Abstract
An apparatus for forming a wave form for a stent from a wire
includes a first forming member configured to move substantially
parallel to a first axis and to move substantially parallel to a
second axis that is orthogonal to the first axis, and a second
forming member configured to move substantially parallel to the
first axis and to move substantially parallel to the second axis.
The second forming member is positioned opposite from the first
forming member relative to the second axis along which the wire is
configured to travel. The apparatus includes a controller
configured to control movement of the first forming member relative
to the wire and to control movement of the second forming member
relative to the wire so that the first forming member and the
second forming member deform the wire in opposite directions to
form a portion of the wave form.
Inventors: |
Hoff; Mark; (Windsor,
CA) ; Moore; Daniel; (Santa Rosa, CA) ;
Craven; Michael; (Santa Rosa, CA) ; Pellegrini;
Gianfranco; (Santa Rosa, CA) ; Griswold; Erik;
(Mill Valley, CA) |
Correspondence
Address: |
MEDTRONIC VASCULAR, INC.;IP LEGAL DEPARTMENT
3576 UNOCAL PLACE
SANTA ROSA
CA
95403
US
|
Assignee: |
MEDTRONIC VASCULAR, INC.
Santa Rosa
CA
|
Family ID: |
42991058 |
Appl. No.: |
12/428581 |
Filed: |
April 23, 2009 |
Current U.S.
Class: |
140/123 ;
72/372 |
Current CPC
Class: |
B21F 45/008 20130101;
B21F 1/04 20130101; A61F 2/90 20130101 |
Class at
Publication: |
140/123 ;
72/372 |
International
Class: |
B21F 45/00 20060101
B21F045/00 |
Claims
1. An apparatus for forming a wave form for a stent from a wire,
the apparatus comprising: a first forming member configured to move
substantially parallel to a first axis and to move substantially
parallel to a second axis that is orthogonal to the first axis; a
second forming member configured to move substantially parallel to
the first axis and to move substantially parallel to the second
axis, the second forming member being positioned opposite from the
first forming member relative to the second axis along which the
wire is configured to travel; and a controller configured to
control movement of the first forming member relative to the wire
and to control movement of the second forming member relative to
the wire so that the first forming member and the second forming
member deform the wire in opposite directions to form a portion of
the wave form.
2. The apparatus according to claim 1, further comprising a first
actuator configured to move the first forming member substantially
parallel to the first axis and substantially parallel to the second
axis, wherein the first actuator is configured to be controlled by
the controller.
3. The apparatus according to claim 1, further comprising a second
actuator configured to move the second forming member substantially
parallel to the first axis and substantially parallel to the second
axis, wherein the second actuator is configured to be controlled by
the controller.
4. The apparatus according to claim 1, wherein the first forming
member comprises a first engaging surface configured to engage the
wire when the first forming member is moved in a first direction
substantially parallel to the first axis, and wherein the second
forming member comprises a second engaging surface configured to
engage the wire when the second forming member is moved in a second
direction that is substantially opposite to the first
direction.
5. The apparatus according to claim 4, wherein the first engaging
surface and the second engaging surface have substantially the same
configuration.
6. A method for forming a wave form for a stent from a wire, the
method comprising: deforming the wire by moving a first forming
member in a first direction substantially perpendicular to a wire
axis defined by the wire prior to being deformed; deforming the
wire by moving a second forming member located on a first side of
the first forming member in a second direction that is
substantially opposite to the first direction; moving the first
forming member away from the wire; moving the first forming member
in a third direction substantially parallel to the wire axis to a
position on an opposite side of the second forming member; and
deforming the wire by moving the first forming member in the first
direction.
7. The method according to claim 6, further comprising: moving the
second forming member in the first direction away from the wire;
moving the second forming member in the third direction to a
position on an opposite side of the first forming member so that
the first side of the first forming member faces the second forming
member; and deforming the wire by moving the second forming member
in the second direction.
8. The method according to claim 7, further comprising: moving the
first forming member and the second forming member away from the
wire; and advancing the wire in the third direction.
9. The method according to claim 6, wherein the first forming
member and the second forming member deform the wire substantially
the same amount.
10. The method according to claim 6, wherein the wire has a
diameter in a range between about 0.0025'' and about 0.0050''.
11. An apparatus for forming a wave form for a stent from a wire,
the apparatus comprising: a plurality of first forming members
spaced apart from one another along a wire axis, each first forming
member being configured to move substantially parallel to the wire
axis and to move substantially parallel to a second axis that is
orthogonal to the wire axis; a plurality of second forming members
spaced apart from one another along the wire axis so that at least
one of the second forming members is in between two of the first
forming members along the wire axis, each second forming member
being configured to move substantially parallel to the wire axis
and to move substantially parallel to the second axis; and a
controller configured to control movement of the first forming
members and movement of the second forming members so that the
first forming members and the second forming members deform the
wire in opposite directions to form a portion of the wave form.
12. The apparatus according to claim 11, further comprising a
plurality of first actuators, each of which being configured to
move a respective first forming member substantially parallel to
the wire axis and substantially parallel to the second axis,
wherein the first actuators are configured to be controlled by the
controller.
13. The apparatus according to claim 11, further comprising a
plurality of second actuators, each of which being configured to
move a respective second forming member substantially parallel to
the wire axis and substantially parallel to the second axis,
wherein the second actuators are configured to be controlled by the
controller.
14. The apparatus according to claim 1, wherein each of the first
forming members comprises a first engaging surface configured to
engage the wire when the first forming member is moved in a first
direction substantially parallel to the second axis, and wherein
each of the second forming members comprises a second engaging
surface configured to engage the wire when the second forming
member is moved in a second direction that is substantially
opposite to the first direction.
15. The apparatus according to claim 14, wherein the first engaging
surfaces and the second engaging surfaces have substantially the
same configuration.
16. A method for forming a stent from a wire, the method
comprising: deforming the wire with a plurality of first forming
members by moving the first forming members in a first direction;
deforming the wire with a plurality of second forming members by
moving the second forming members in a second direction that is
substantially opposite the first direction; moving the first
forming members and the second forming members in a third direction
that is substantially orthogonal to the first and second
directions; moving the first forming members away from the wire in
the second direction; moving the second forming members away from
the wire in the first direction; and advancing the wire in the
third direction.
17. The method according to claim 16, wherein said deforming the
wire with the plurality of first forming members and said deforming
the wire with the plurality of second forming members occurs at
substantially the same time.
18. The method according to claim 16, wherein the first forming
members and the second forming members deform the wire
substantially the same amount.
19. The method according to claim 16, wherein the wire has a
diameter in a range between about 0.0025'' and about 0.0050''.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is generally related to an apparatus
and method for forming a wave form for a stent. More particularly,
the present invention is related to an apparatus and method for
forming the wave form from a wire.
[0003] 2. Background of the Invention
[0004] A stent is typically a hollow, generally cylindrical device
that is deployed in a body lumen from a radially contracted
configuration into a radially expanded configuration, which allows
it to contact and support a vessel wall. A plastically deformable
stent can be implanted during an angioplasty procedure by using a
balloon catheter bearing a compressed or "crimped" stent, which has
been loaded onto the balloon. The stent radially expands as the
balloon is inflated, forcing the stent into contact with the body
lumen, thereby forming a support for the vessel wall. Deployment is
effected after the stent has been introduced percutaneously,
transported transluminally, and positioned at a desired location by
means of the balloon catheter.
[0005] Stents may be formed from wire(s), may be cut from a tube,
or may be cut from a sheet of material and then rolled into a
tube-like structure. While some stents may include a plurality of
connected rings that are substantially parallel to each other and
are oriented substantially perpendicular to a longitudinal axis of
the stent, others may include a helical coil that is wrapped around
the longitudinal axis at a non-perpendicular angle.
[0006] A stent that includes a helical coil may be formed from a
single wire that includes a wave form that is configured to allow
the stent to radially expand. In view of the small size of the
stents, it may be difficult to form a stent from a single wire
while controlling the wave form so that the end result is a stent
that expands uniformly along its length.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention describe an apparatus
and method for forming a wave form for a stent from a single
wire.
[0008] According to an aspect of the present invention, there is
provided an apparatus for forming a wave form for a stent from a
wire. The apparatus includes a first forming member configured to
move substantially parallel to a first axis and to move
substantially parallel to a second axis that is orthogonal to the
first axis, and a second forming member configured to move
substantially parallel to the first axis and to move substantially
parallel to the second axis. The second forming member is
positioned opposite from the first forming member relative to the
second axis along which the wire is configured to travel. The
apparatus includes a controller configured to control movement of
the first forming member relative to the wire and to control
movement of the second forming member relative to the wire so that
the first forming member and the second forming member deform the
wire in opposite directions to form a portion of the wave form.
[0009] According to an aspect of the present invention, there is
provided a method for forming a wave form for a stent from a wire.
The method includes deforming the wire by moving a first forming
member in a first direction substantially perpendicular to a wire
axis defined by the wire prior to being deformed, and deforming the
wire by moving a second forming member located on a first side of
the first forming member in a second direction that is
substantially opposite to the first direction. The method includes
moving the first forming member away from the wire, moving the
first forming member in a third direction substantially parallel to
the wire axis to a position on an opposite side of the second
forming member, and deforming the wire by moving the first forming
member in the first direction.
[0010] According to an aspect of the present invention, there is
provided an apparatus for forming a wave form for a stent from a
wire. The apparatus includes a plurality of first forming members
spaced apart from one another along a wire axis. Each first forming
member is configured to move substantially parallel to the wire
axis and to move substantially parallel to a second axis that is
orthogonal to the wire axis. The apparatus also includes a
plurality of second forming members spaced apart from one another
along the wire axis so that at least one of the second forming
members is in between two of the first forming members along the
wire axis. Each second forming member is configured to move
substantially parallel to the wire axis and to move substantially
parallel to the second axis. The apparatus includes a controller
configured to control movement of the first forming members and
movement of the second forming members so that the first forming
members and the second forming members deform the wire in opposite
directions to form a portion of the wave form.
[0011] According to an aspect of the present invention, there is
provided a method for forming a stent from a wire. The method
includes deforming the wire with a plurality of first forming
members by moving the first forming members in a first direction,
deforming the wire with a plurality of second forming members by
moving the second forming members in a second direction that is
substantially opposite the first direction, and moving the first
forming members and the second forming members in a third direction
that is substantially orthogonal to the first and second
directions. The method includes moving the first forming members
away from the wire in the second direction, moving the second
forming members away from the wire in the first direction, and
advancing the wire in the third direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Embodiments of the invention will now be described, by way
of example only, with reference to the accompanying schematic
drawings in which corresponding reference symbols indicate
corresponding parts, and in which:
[0013] FIG. 1 is a schematic view of an apparatus for forming a
wave form for a stent from a wire when the wire is first fed into
the apparatus, and a first forming member and a second forming
member are in home positions;
[0014] FIG. 2 is a schematic view of the apparatus of FIG. 1 when
the first forming member engages and deforms the wire;
[0015] FIG. 3 is a schematic view of the apparatus of FIG. 2 when
the second forming member engages and deforms the wire;
[0016] FIG. 4 is a schematic view of the apparatus of FIG. 3 when
the second forming member moves away from the wire;
[0017] FIG. 5 is a schematic view of the apparatus of FIG. 4 when
the second forming member moves in a direction substantially
parallel to the wire;
[0018] FIG. 6 is a schematic view of the apparatus of FIG. 5 when
the second forming member engages and deforms the wire;
[0019] FIG. 7 is a schematic view of the apparatus of FIG. 6 when
the first forming member disengages the wire;
[0020] FIG. 8 is a schematic view of the apparatus of FIG. 7 when
the first forming member moves in the direction substantially
parallel to the wire;
[0021] FIG. 9 is a schematic view of the apparatus of FIG. 8 when
the first forming member engages and deforms the wire;
[0022] FIG. 10 is a schematic view of the apparatus of FIG. 9 when
the first forming member and the second forming member disengage
the wire;
[0023] FIG. 11 is a schematic view of the apparatus of FIG. 10 when
the wire is moved relative to the apparatus and the first forming
member and the second forming member return to their respective
home positions;
[0024] FIG. 12 is a schematic view of the apparatus of FIG. 11 when
the first forming member engages and deforms the wire;
[0025] FIG. 13 is a schematic view of a first waveform produced
with the apparatus of FIGS. 1-12;
[0026] FIG. 14 is a schematic view of a second waveform produced
with the apparatus of FIGS. 1-12;
[0027] FIG. 15 is a schematic view of another embodiment of an
apparatus for forming a wave form for a stent from a wire when the
wire is first fed into the apparatus, and a plurality of first
forming members and a plurality of second forming members are in
their respective home positions;
[0028] FIG. 16 is a schematic view of the apparatus of FIG. 15 when
the first forming members and the second forming members engage and
deform the wire to form the wave form;
[0029] FIG. 17 is a schematic view of the apparatus of FIG. 15 when
the first forming members and the second forming members disengage
and move away from the wire;
[0030] FIG. 18 is a schematic view of the apparatus of FIG. 15 when
the wire is moves relative to the apparatus, and the first forming
members and the second forming members return to their respective
home positions;
[0031] FIG. 19 is a schematic block diagram that illustrates
communication between a controller and other parts of the apparatus
of FIGS. 1-12; and
[0032] FIG. 20 is a schematic block diagram that illustrates
communication between a controller and other parts of the apparatus
of FIGS. 15-18.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0033] The following detailed description is merely exemplary in
nature and is not intended to limit the invention or the
application and use of the invention. Furthermore, there is no
intention to be bound by any expressed or implied theory presented
in the preceding technical field, background, brief summary or the
following detailed description.
[0034] FIG. 1 schematically illustrates a portion of an apparatus
10 for forming a wave form for a stent from a wire 12. A supply 14
of the wire 12 is provided to the apparatus 10. In an embodiment,
the supply 14 may include a spool upon which the wire 12 is wound.
The wire 12 may have any suitable diameter for the intended stent
application. In an embodiment, the wire 12 may have a diameter
between about 0.0025'' and about 0.0050''.
[0035] The supply 14 may be mounted outside of the apparatus 10 or
within the apparatus 10 so that the wire 12 may be fed in a first
direction 1D into a wire forming area 16 of the apparatus 10 via an
inlet 15. As illustrated, the wire 12 extends through the wire
forming area 16 substantially along an axis, and exits the wire
forming area 16 via an outlet 17. A suitable clamp 18 may be
located just outside the wire forming area 16, as illustrated, or
may be located within the wire forming area 16. The illustrated
embodiment is not intended to be limiting in any way. The clamp 18
is configured to clamp the wire 12 so that tension may be applied
to the wire 12 as the wire 12 is formed into a predetermined shape,
as discussed in further detail below.
[0036] The apparatus 10 also includes a first forming member 20 and
a second forming member 22, each of which being located within the
wire forming area 16. As illustrated, the first forming member 20
is located on one side of the wire 12 and the second forming member
22 is located on an opposite side of the wire 12 as compared to the
first forming member 20. The first forming member 20 and the second
forming member 22 each have a substantially elongated shape,
similar to a finger, that is oriented substantially perpendicular
to a (longitudinal) wire axis that is defined by the wire 12, as
illustrated.
[0037] The first forming member 20 includes a wire engaging surface
24 that is configured to engage the wire 12 when the first forming
member 20 is moved in a second direction 2D that is substantially
orthogonal to the first direction 1D. After the wire engaging
surface 24 has engaged the wire 12, the first forming member 20
continues to move in the second direction 2D to deform the wire 12,
as shown in FIG. 2. When the desired deformation is obtained,
movement of the first forming member 20 in the second direction 2D
is stopped and the wire 12 is held in place by the first forming
member 20, as well as the clamp 18. Although the wire engaging
surface 24 of the first forming member 20 is illustrated as having
a triangular configuration, such a configuration is shown for
schematic purposes. For example, the wire engaging surface 24 may
be more rounded and may have a tip that has a radius that is
substantially the same as the inner radius of the desired shape of
the deformed wire. The illustrated embodiment is not intended to be
limiting in any way.
[0038] The first forming member 20 may be moved in the second
direction 2D by a first actuator 26, which may be configured to
move in the first direction 1D along a suitable structure, such as
a rail 28. Such X-Y actuators are known in the actuator art and
therefore will not be discussed in further detail herein. The first
actuator 26 may be in communication with a controller 30 (as shown
in FIG. 19) that is programmed to determine the X-Y position of the
first forming member 20 relative to the wire 12 at any given time.
The controller 30 is configured to signal the first actuator 26 to
move the first forming member 20 to the desired coordinates within
the wire forming area 16, as discussed in further detail below.
[0039] Similarly, the second forming member 22 includes a wire
engaging surface 34 that is configured to engage the wire 12 when
the second forming member 22 is moved in a third direction 3D that
is substantially opposite to the second direction 2D and orthogonal
to the first direction 1D. After the wire engaging surface 34 has
engaged the wire 12, the second forming member 22 continues to move
in the third direction 3D to deform the wire 12, as shown in FIG.
3. When the desired deformation is obtained, movement of the second
forming member 22 in the third direction 3D is stopped and the wire
12 is momentarily held in place by both the first forming member 20
and the second forming member 22. Although the wire engaging
surface 34 of the second forming member 22 is illustrated as having
a triangular configuration, such a configuration is shown for
schematic purposes. For example, like the wire engaging surface 24
of the first forming member 20, the wire engaging surface 34 may be
more rounded and may have a tip that has a radius that is
substantially the same as the inner radius of the desired shape of
the deformed wire. The illustrated embodiment is not intended to be
limiting in any way.
[0040] In an embodiment, the wire engaging surface 24 of the first
forming member 20 and the wire engaging surface 34 of the second
forming member 22 have substantially the same shape. In an
embodiment, the shapes of the wire engaging surface 24 of the first
forming member 20 and the wire engaging surface 34 of the second
forming member 22 are different.
[0041] The second forming member 22 may be moved in the third
direction 3D, as well as the second direction 2D and first
direction 1D, by a second actuator 36 that is configured to move in
the first direction 1D along a suitable structure, such as a rail
38. Actuation of the second actuator 36 may be controlled by the
controller 30, which also determines the X-Y position of the second
forming member 22 relative to the wire 12 at any given time. The
controller 30 may be configured to signal the second actuator 36 to
move the second forming member 22 to the desired coordinates within
the wire forming area 16.
[0042] As illustrated in FIG. 4, after the second forming member 22
has deformed the wire 12, the first actuator 26 may move the first
forming member 20 in the third direction 3D away from the wire 12.
The first actuator 26 may then move along the rail 28 to move the
first forming member 20 in the first direction 1D, as illustrated
in FIG. 5, to a position that is downstream of the second forming
member 22 relative to the direction of travel of the wire 12 along
the axis, so that the first forming member 20 is on an opposite
side of the second forming member 22 as compared to its previous
position (shown in FIG. 3). Once the first forming member 20 is
positioned at the desired location relative to the second forming
member 22, the first actuator 26 moves the first forming member 20
in the second direction 2D so that the wire engaging surface 24 of
the first forming member 20 engages the wire 12 and deforms the
wire 12 to the desired amount of deformation, as shown in FIG.
6.
[0043] The first forming member 20 (and the clamp 18) may then be
used to hold the wire 12 in position as the second actuator 36
moves the second forming member 22 away from the wire 12 in the
second direction, as illustrated by FIG. 7. After the second
forming member 22 has cleared the wire 12, the second actuator 36
may move along the rail 38 so that the second forming member 22
moves in the first direction 1D to a position that is downstream of
the first forming member 20 relative to the direction of travel of
the wire 12 along the axis, as shown in FIG. 8. The second forming
member 22 may then be moved by the second actuator 36 in the third
direction 3D so that the wire engaging surface 34 of the second
forming member 22 engages the wire 12 and deforms the wire 12 to
the desired amount of deformation, as illustrated by FIG. 9. This
process may be repeated until the wire 12 within the wire forming
area 16 has been deformed to its desired wave form 40.
[0044] As illustrated by FIG. 10, after the wire 12 has been
deformed to its desired wave form 40 in the wire forming area 16,
the first forming member 20 may be moved in the third direction 3D
by the first actuator 26 and the second forming member 22 may be
moved in the second direction 2D by the second actuator 36 to
positions that are clear of the wire 12. At substantially the same
time, the clamp 18 may be actuated to release the wire 12. The wire
12 may then be advanced in the first direction 1D so that the wave
form 40 that was created in the wave forming area 16 may be moved
out of the wave forming area 16 and a straight length of wire 12
may enter the wire forming area 16 via the inlet 15, as shown in
FIG. 11. The clamp 18 may be configured to grasp the wire form 40
in a manner that will not deform, i.e., straighten or otherwise
alter, the wire form 40.
[0045] FIG. 12 illustrates the beginning of a second cycle of the
apparatus 10 to create a wire form for the next segment of the wire
12. As illustrated, the first forming member 20 is moved by the
first actuator 26 in the second direction 2D to engage and deform
the wire 12 in the same manner as discussed above with reference to
FIG. 2. The sequence of movement of the first forming member 20 and
the second forming member 22 may be the same as the sequence
illustrated by FIGS. 3-11, and may be further repeated until the
desired length of wire 12 has been imparted with the desired wave
form 40. For example, FIGS. 13 and 14 illustrate embodiments of
wave forms 42, 44, respectively, that may be produced on the
apparatus 10. As illustrated, the wave forms 42, 44 have generally
sinusoidal shapes, each of which having curves that have
substantially the same amplitude and frequency. The amplitude of
the curves may be varied by deforming the wire 12 in the apparatus
10 to a greater or lesser extent with the first and second forming
members 20, 22. For example, to create the wire form 44 shown in
FIG. 14, the first and second forming member 20, 22 may be moved
greater distances after their respective wire engaging surfaces 24,
34 have engaged the wire 12, as compared to the distances travelled
by the first and second forming members 20, 22 after the wire
engaging surfaces 24, 34 have engaged the wire 12 to form the wire
form 42 illustrated by FIG. 13. Of course, many other shapes may be
formed and the embodiments illustrated in FIGS. 13 and 14 are not
intended to be limiting in any way.
[0046] For example, because the movement of the wire 12, the first
forming member 20, and the second forming member 22 are controlled
by the controller 30, each wave that is formed may be different,
i.e., may have a different amplitude, wavelength, shape, etc., as
compared to adjacent waves. In an embodiment, each wave of the wave
form may have a unique amplitude and wavelength.
[0047] FIG. 15 illustrates a portion of an apparatus 100 for
forming a wave form for a stent from the wire 112. Like the
embodiment illustrated in FIGS. 1-12, the wire 112 is provided to
the apparatus 100 by a supply 114, which may include a spool upon
which the wire 112 is wound. The wire 112 may be fed in the first
direction 1D into an inlet 115 of a wire forming area 116 of the
apparatus 100. As illustrated, the wire 112 extends through the
wire forming area 116 substantially along an axis, and exits the
wire forming area 116 via an outlet 117. A suitable clamp 118 may
be located just outside the wire forming area 116, as illustrated,
or may be located within the wire forming area 116. The illustrated
embodiment is not intended to be limiting in any way. The clamp 118
is configured to clamp the wire 112 so that tension may be applied
to the wire 112 as the wire 112 is formed into a predetermined
shape, as discussed in further detail below.
[0048] The apparatus 100 also includes a plurality of first forming
members 120 and a plurality of second forming members 122, each of
which being located within the wire forming area 116. As
illustrated, the first forming members 120 are located on one side
of the wire 112 and the second forming members 122 are located on
an opposite side of the wire 112 as compared to the first forming
members 120. The first forming members 120 and the second forming
members 122 have substantially elongated shapes, similar to the
first and second forming members 20, 22 described above.
[0049] Each of the first forming members 120 includes a wire
engaging surface 124 that is configured to engage and the wire 112
when the first forming members 120 are moved in a second direction
2D' that is substantially orthogonal to the first direction 1D.
After the wire engaging surfaces 124 have engaged the wire 112, the
first forming members 20 continue to move in the second direction
2D' to deform the wire 112, as shown in FIG. 16.
[0050] Each of the first forming members 120 may be moved in the
second direction 2D' by a respective first actuator 126, all of
which may be configured to move in the first direction 1D along a
suitable structure, such as a rail 128 in a similar manner as
described above with respect to the first actuator 26 and rail 28.
Each of the first actuators 126 may be in communication with a
controller 130 (as shown in FIG. 20) that is programmed to
determine the X-Y position of each of the first forming members 120
relative to the wire 112 at any given time. The controller 130 is
configured to signal the first actuators 126 to move the first
forming members 120 to the desired coordinates within the wire
forming area 116.
[0051] Similarly, each of the second forming members 122 includes a
wire engaging surface 134 that is configured to engage the wire 112
when the second forming members 122 are moved in a third direction
3D'. After the wire engaging surfaces 134 have engaged the wire
112, the second forming members 122 continue to move in the third
direction 3D' to deform the wire 112, as shown in FIG. 16. When the
desired deformation is obtained, movement of the second forming
members 122 in the third direction 3D' is stopped and the wire 112
is momentarily held in place by the first forming members 120 and
the second forming members 122.
[0052] In an embodiment, all of the wire engaging surfaces 124 of
the first forming members 120 have substantially the same shape,
and the wire engaging surfaces 134 of the second forming members
122 have substantially the same shape, and also have substantially
the same shape as the wire engaging surfaces 124 of the first
forming members 120. In an embodiment, the shapes of the wire
engaging surfaces 124 of the first forming members 20 and the wire
engaging surfaces 134 of the second forming members 122 are
different. In an embodiment, each of the wire engaging surfaces
124, 134 are different. The illustrated embodiment is not intended
to be limiting in any way.
[0053] As illustrated in FIG. 16, the first actuators 126 move the
first forming members 120 in the first direction 1D as well as the
second direction 2D'. At substantially the same time, the second
actuators 136 move the second forming members 122 in the first
direction 1D as well as the third direction 3D' so that the wire
112 is engaged by the wire engaging surfaces 124, 134 at about the
same time. In an embodiment, the wire engaging surfaces 124 of the
first forming members 120 engage the wire 112 before the wire
engaging surfaces 134 of the second forming members 122 engage the
wire 112. In an embodiment, the wire engaging surfaces 134 of the
second forming members 122 engaging the wire 112 before the wire
engaging surfaces 124 of the first forming members 120. In an
embodiment, each of the first forming members 120 and the second
forming members 122 may be actuated at different times so that the
respective wire engaging surfaces 124, 134 engage the wire 112 at
different times. The controller 130 may be programmed so that the
desired sequence of actuations may occur to create the desired wave
form in the wire 112.
[0054] For example, in an embodiment, the first forming member 120
that is closest to the clamp 118 may be actuated first, and the
second forming member 122 that is closest to the clamp 118 may be
actuated second. The remaining first and second forming members may
be actuated in an alternating sequence until the first forming
member that is closest to the inlet 115 of the wire forming area
116 is actuated. All of the forming members 120, 122 may be
retracted from the wire 112 at the same time, and the wire may be
advanced so that the portion of the wave form that was formed by
the first forming member that is closest to the inlet 115 is
aligned with the first forming member that is closest to the clamp
118. The sequence may repeat itself, starting with the first
forming member engaging the already formed portion of the wire
form. The supply 114 may be configured to automatically advance the
wire 112 as the wire 112 is deformed into the wave form, as long as
a slight tension is maintained on the wire 112 so that the wire 112
remains straight within the wire forming area 116 until it is
deformed.
[0055] As illustrated in FIG. 17, after a wave form 140 has been
formed, the first forming members 120 may be moved in the third
direction 3D' to disengage from the wire 112, and the second
forming members 122 may be moved in the second direction 2D' to
disengage from the wire 112. The controller 130 may then signal the
clamp 118 to open and may signal the supply 114 to advance the wire
112 a predetermined amount so that a new section of wire 112 may be
advanced into the wire forming area 116, as shown in FIG. 18. At
about the same time, the first and second forming members 120, 122
may be moved along their respective rails 128, 138 in the fourth
direction 4D so that another cycle may begin. Once the clamp 118 is
closed, the process may be repeated until the desired amount of
wire 112 has been formed into the desired wave form.
[0056] For example, because the movement of the wire 112, the first
forming members 120, and the second forming members 122 are
controlled by the controller 130, each wave that is formed may be
different, i.e., may have a different amplitude, wavelength, shape,
etc., as compared to adjacent waves. In an embodiment, each wave of
the wave form may have a unique amplitude and wavelength.
[0057] FIG. 19 schematically illustrates communication between the
controller 30 and other parts of the apparatus 10 that are
illustrated in FIGS. 1-12. As illustrated, the controller 30 is
configured to communicate with the supply 14, the clamp 18, the
first actuator 26, and the second actuator 36. As discussed above,
the first actuator 26 is configured to move the first forming
member 20 in both X and Y directions (using the coordinates
depicted in FIG. 1). Similarly, the second actuator 36 is
configured to move the second forming member 22 in both X and Y
directions. Once the desired wave form has been communicated to the
controller 30, and the controller 30 is able to access a computer
readable medium that contains a method for forming the desired wave
form, as described herein, the controller 30 may signal the supply
14, the clamp 18, the first actuator 26, and the second actuator 36
so that the apparatus 10 forms the desired wave form. Although a
particular sequence of movement of the forming members 20, 22 is
described above, other sequences may be programmed for execution by
the controller. For example, in an embodiment, the second forming
member 22 may be moved prior to the first forming member 20.
[0058] FIG. 20 schematically illustrates communication between the
controller 130 and other parts of the apparatus 100 that are
illustrated in FIGS. 15-18. As illustrated, the controller 130 is
configured to communicate with the supply 114, the clamp 118, the
first actuators 126, and the second actuators 136. As discussed
above, the first actuators 126 are each configured to move a
corresponding first forming member 120 in both X and Y directions
(using the coordinates depicted in FIG. 15). Similarly, the second
actuators 136 are each configured to move a corresponding second
forming member 122 in both X and Y directions. Once the desired
wave form has been communicated to the controller 130, and the
controller 130 is able to access a computer readable medium that
contains a method for forming the desired wave form, as described
herein, the controller 130 may signal the supply 114, the clamp
118, the first actuators 126, and the second actuators 136 so that
the apparatus 100 forms the desired wave form.
[0059] While at least one exemplary embodiment has been presented
in the foregoing detailed description of the invention, it should
be appreciated that a vast number of variations exist. It should
also be appreciated that the exemplary embodiment or exemplary
embodiments are only examples, and are not intended to limit the
scope, applicability, or configuration of the invention in any way.
Rather, the foregoing detailed description will provide those
skilled in the art with a convenient roadmap for implementing an
exemplary embodiment of the invention, it being understood that
various changes may be made in the function and arrangement of
members described in an exemplary embodiment without departing from
the scope of the invention as set forth in the appended claims.
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