Abstract: A wire sheave particularly adapted for magnet wire coating apparatus. The sheave has an outer radial structure with an outer surface containing a wire groove. The outer radial structure also contains a chamber suitable for containing a liquid or gas. The apparatus is used to preheat wire before it passes through the coating solution.

Abstract: A magnet wire oven for an in-line drawing fabrication process is controlled by means of a local operator control station having a plurality of menu screens stored therein for operator call-up and control via a remote controller for controlling a plurality of oven parameters. The remote controller is located in an output of the way location so as to efficiently utilize floorspace while at the same time controlling a large number of parameters in one main controller unit. The local operator station comprises a local signal processor, a keyboard, a display and an input/output port. The remote controller comprises a remote signal processor, a multiplexer and a plurality of analog loop controllers. The remote controller may also include either analog or digital input/output devices or both.

Abstract: The invention discloses a high solids wire enamel having a surprisingly low viscosity. The enamel comprises a mixture of high molecular weight and low molecular weight linear hydroxy polyethers, a phenolic resin, an isocyanate and possibly a melamine. The resulting enamel has excellent flexibility and resistance to crazing.

Abstract: A heat deformable tube having a melt liner of noncross-linked, thermoplastic material, such that upon heating to a temperature high enough to cause the tube to return to its original shape; the melt liner melts and encapsulates the substrate.

Abstract: A cable shielding system is disclosed wherein corrugated metal shielding has its edges bent to a predetermined configuration prior to being formed about the cable. Upon being formed around the cable, the sheathing with the pre-bent edges forms a closed passage way within the seam for receiving an adhesive. The pre-bent edge configuration reduces the possibility that the edge of the metallic sheathing will damage an externally applied plastic sheath.

Abstract: This invention relates to a method for removing an oxide scale from the surface of a hot rolled copper rod in an in-line process. The method comprises the steps of passing the rod through a chamber containing a reducing atmosphere, the chamber being immediately adjacent to the exit end of the rod rolling mill. The rod passes through the hydrogen containing chamber while it is still hot from the rolling operation, and the reducing atmosphere reduces the oxide scale to metallic copper. After passing through the chamber, the rod is cooled in an aqueous bath and then coiled.

Abstract: A palletized structure for containing a plurality of wire spools or pails containing wire is disclosed. The palletized structure includes a formed cap structure with an integrally formed beam structure which preserves the rigidity of the cap structure when the palletized structure is subjected to motion and shock forces normally encountered in loading, shipping or storage of wire spools or pails. The cap structure retains the relative position of the spools or pails within the palletized structure.

Abstract: A wire dispensing and storage box is provided with a plurality of flap tabs appending to the top and bottom portions of the box which are inserted within a plurality of flap slots within the side portions of the box, respectively, so that the top and bottom portions of the box will not interfere with the paying off of the wire from the coil. The flap slot/flap tab construction helps prevent the cones, which provide integrity to the box and help support the wire therein, and locking tabs, which lock the box, of the top of the box and the cones and locking tabs of the bottom of the box from contacting each other in the center of the box thereby facilitating the dispensing of the wire.

Abstract: Methods for cleaning in-process wire are developed. In one embodiment a moving string loops around the wire and advances to present a clean surface to remove dirt from the surface of the moving wire.

Abstract: A threading bar and a process for using the threading bar with a wire coating apparatus having parallel transport cables is disclosed. The threading bar comprises a body portion suitable for attaching wires thereto, and a gripping mechanism which is used to selectively engage a portion of a transport cable so as to secure the body portion to the transport cable. Process steps include the use of such a threading bar to draw wire through a wire coating apparatus.

Abstract: In a magnet wire fabrication process in which the drawing of wire is "in-line" with the enameling process, it is often a requirement that the drawing machines be supplied with electrical power from the utility grid rather than relying on an "in-house," closely regulated supply of electrical power. In such cases, during voltage dips on the grid, the drawing machine motors will slow down while the wires continue to be pulled from the drawing machine at the same speed as before. A wire accumulator is interposed between the drawing machines and the enameling oven to prevent breakage of wire by providing an accumulation of wire to be used in the event of such a voltage dip. The present invention discloses an apparatus for controlling the various channels of the accumulator so as to provide roughly equivalent amounts of wire in each channel so that the integrity of all channels during a power dip is assured. A central operator control station for effecting the desired control is disclosed.

Abstract: Disclosed is a magnet wire composition comprising the reaction product of a polyamide resin, a titanate catalyst, and a solvolytic agent admixed with a blocked polyisocyanate and hydroxylated polyester. Also disclosed is a method of applying such magnet wire enamel to a magnet wire substrate and additionally disclosed is a method for making such magnet wire enamel.

Abstract: The fabrication of magnet wire in an "in-line" drawing-enameling process is monitored by a local operator control station having an alarm display format screen stored therein for operator call-up via a remote controller for displaying a plurality of alarmed parameters in a time ordered sequence. The local operator station includes a local signal processor, a keyboard, a display and an input/output port. The remote controller includes a remote signal processor, a digital input/output device, and a plurality of modular cassette tape players. The first to occur alarm is sensed and is verbally annunciated while, at the same time, the alarm signal is stored and time tagged. If one or more alarms subsequently occur, an operator may wish to determine the nature of these later occurring alarms and the exact sequence in which the alarms occurred.

Abstract: Method and apparatus for monitoring a rod mill and flexible wire drawn and annealed from a stiff coil of rod in the rod mill are disclosed. The fault signals provided by an eddy-current tester are counted on a per unit time basis in order to permit the detection of rod mill problems before serious deterioration of the mill occurs. This is accomplished by direct observation of an increasing rate of fault signal occurrence. A totalized fault signal count is also provided to aid in detecting low quality wire. This is accomplished by direct observation of uniformly high levels of fault signals. A control function is disclosed whereby the rod mill is shutdown in the presence of a high rate of increase in fault signal occurrences. A "change coil" message may be sent upon detecting uniformly high levels of faults. Fault signals are stored and identified for purposes of traceability.

Abstract: A magnet wire enamel based on polyamide resins is disclosed in which the molecular weight of the polyamide resin is reduced through an equilibration reaction with a solvolytic agent and a titanate catalyst. Also disclosed is a method of applying said enamel to a magnet wire substrate and the resulting enameled magnet wire.

Abstract: A corrugated, highly flexible mica insulating structure is disclosed which comprises one or more layers of mica paper impregnated with about 5 percent to about 25 percent by weight of a flexible polysiloxane resin having about 1 percent to about 4 percent by weight of an organic titanate and about 0.5 percent to about 2 percent by weight of a naphthenate based on polymer solids, said resin binder being partially cured or B-staged wherein the resulting papers are then corrugated to impart greater flexibility without a substantial loss of its dielectric properties.

Abstract: A wire prebreak/break sensor is disclosed for use in a low cost verbal annunciator system for use in monitoring a wire fabrication process. Wire exiting a drawing machine is accumulated and has its tension controlled by a dancer arm. According to the present invention, a wire accumulator having a plurality of channels is used as a wire prebreak/break sensor. The accumulator comprises a plurality of rods having sheaves on a end of each supported on a support structure to which each rod is pivoted on an axis. A plurality of position sensors are responsive to the positions of the various rods and provide a position signal having a magnitude indicative thereof. An operator input device is responsive to operator initiated input action for providing input signals indicative of wire gauge. A signal processor is responsive to the position signals and to the operator input signals and retrieves a pair of boundary signals in response to the magnitude of the gauge size input signals.

Abstract: Processes for providing an inert gas protective atmosphere during shut down periods of a copper melting shaft furnace are described. Upon shut down of the furnace, liquid nitrogen is introduced into the furnace interior and forms gaseous nitrogen upon vaporization. A two-stage process is employed with the initial introduction of liquid nitrogen at a high rate to flush out all oxygen bearing atmospheres from the furnace, followed by the introduction of liquid nitrogen at a lower rate sufficient to maintain the protective nitrogen atmosphere.

Abstract: The insulation of a plurality of grounded wires may be tested subsequent to fabrication and prior to spooling by use of a corresponding plurality of modular circuit boards installed in a continuity tester. Each modular circuit board has its own on board DC power supply and clock generator for enhancing isolation, thereby decreasing crosstalk between channels and reducing spurious "sympathetic" faults. AC or DC high voltage testing may be selected. Isolation is also enhanced by using a sheaves separated by teflon insulators, all mounted on a common rod.

Abstract: A highly flexible mica insulating structure is disclosed which comprises one or more mica papers impregnated with about 5 percent to about 25 percent by weight of a flexible polysiloxane resin having about 1 percent to about 4 percent by weight of an alkoxy titanate and about 0.5 percent to about 2 percent by weight of a naphthenate based on polymer solids, said resin binder being partially cured or B-staged. Such mica products have excellent flexibility, structural integrity and improved moisture resistance.