Abstract: A high speed method of producing continuous length magnet wire coated with a high solids content polymer coating composition. Copper or copper alloy wire segments are joined by brazing utilizing a braze whose melting point is greater than 1000.degree. F. and less than 1600.degree. F. The thus formed joint has a tensile strength greater than 27,000 p.s.i., and is capable of being conformed to the circumference of the wire substrate without substantially altering the surface integrity of the wire. The continuous length magnet wire is preheated to an elevated temperature. The preheated wire is coated with a noncirculating polymer enamel composition having a high solids content and a high viscosity at high speed. The enamel coated wire is then cured.

Abstract: The present invention is for a method of applying high solids enamel coatings to magnet wire. The method comprises reducing the viscosity of the enamel to a processable range and then applying the heated enamel to the wire via a felt applicator. The coated wire is then passed through an oven where the enamel is cured. This method provides a process for applying high solids, viscous enamels to fine magnet wire substrates without the disadvantages of solvent dilution. The result is higher quality coatings, faster processing time and reduced process costs.

Abstract: The present invention discloses a method and apparatus for applying high solids enamels to wire wherein the enamel is heated to lower its viscosity to below about 200 cps, the heated enamel is then passed through a discrete, enclosed passageway in a first felt pad. The wire to be coated is then drawn between the first felt pad and a second felt pad in contact with the first felt pad. The wire is passed substantially perpendicular and in front of the discrete passageway of the first felt pad when it is coated with the enamel. The enamel is then formed uniformly and circumferentially about the wire as it exits the felt pads and cured in a curing oven.