Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: A saw with a monitoring and safety system that utilizes vision and sensors designed to provide user feedback on safety and training. The saw having a wheel formed of an anodized main body with a non-anodized surface extending along the circumference of the groove of the wheel. The saw having low inertial energy design to stop the blade without mechanically grabbing the blade assuring multiple points of safety detection and triggering. The saw having an automatic guard to protect the user from slipping and hitting the blade even when the saw is not running. The saw being connected to a cloud based system that enables a safer ecosystem and cross statistic sharing of safety parameters.

Abstract: A resistance annealing furnace for annealing a metal wire, strand, string, wire rod or strap having at least two electric axes provided with respective pulleys to convey the metal wire and a DC voltage generator suppliable with an AC voltage to generate an annealing voltage applied between the two electric axes so as to provoke the annealing due to Joule effect. The DC voltage generator has active supplying means supplied with the AC voltage so as to generate an intermediate DC voltage, a pulse width modulator to transform the intermediate voltage into a first PWM voltage with the same amplitude, a voltage transformer to transform the first PWM voltage into a second PWM voltage with a smaller amplitude, and a voltage rectifier stage to transform the second PWM voltage into the annealing voltage.

Abstract: The present invention for eliminating a need for a temperature detecting element adapted to measure the temperature of a roll main body provides an induction heated roll apparatus including: a roll main body; a magnetic flux generating mechanism including an iron core and a winding; and a power supply circuit provided with a control element adapted to control AC current or AC voltage. The apparatus calculates the temperature of the roll main body using an AC current value obtained by an AC current detecting part, an AC voltage value obtained by an AC voltage detecting part, a power factor obtained by a power factor detecting part, a winding resistance value of the winding, and an excitation resistance obtained from characteristics of a relationship between a magnetic flux density and an excitation resistance of a magnetic circuit including the iron core and the roll main body as parameters.

Abstract: A eutectic sensing element includes an electrically conductive core extending along a first axis to define a length. The core is coated with a coated with a eutectic material formulated to provide desirable thermal response characteristics. The eutectic sensing element further includes an insulating fiber layer disposed on an external surface of the electrically conductive. The insulating fiber layer includes a strand that extends along the length of the electrically conductive core.

Abstract: The present invention relates to a battery temperature adjusting system including: a battery unit having a heating pad; a leading wire connected to the battery unit; and a current induction unit surrounding the leading wire, wherein the current induction unit is electrically connected to the heating pad. The battery temperature adjusting system according to the present invention generates the induced current by applying the current induction unit surrounding the leading wire connected to the battery unit, and increases the temperature of the battery unit by supplying the induced current to the heating pad, thereby obtaining a desired battery output in a low-temperature region even without the use of an external power source.

Abstract: Apparatus and method for winding coils of at least one electric wire conductor (W) on a coil support (10, 11, 10?, 11?) comprising a coil support (10,11) wound and assembled on a pole of a core of a dynamo electric machine, or a pole (10?,11?) wound and assembled to form the core of a dynamo electric machine; comprising: a wire dispenser (19), the wire dispenser having a passage portion (18) for the wire and an exit (23?) from where the wire reaches the coil support (10, 11, 10?, 11?) during winding; means (31,32) for pressing on the wire (W) during winding to bend the wire according to a configuration of the coil; means (20) for supporting and rotating the coil support with respect to the dispenser (19) to wind the wire on the coil support (10,11, 10?, 11?); means (40) for applying tension on the wire reaching the dispenser (19); means (24, 24?, 25, 25?, 26, 26?) for moving the dispenser (19) with respect to the coil support (10, 11, 10?, 11?).

Abstract: There is provided a manufacturing method for a composite structure that makes it possible to join a thermoplastic resin molding, which serves as a second member for reinforcement, while at the same time preventing the deformation of a first member to be reinforced. The second member contains magnetic substances in a portion thereof that is to be abutted on the first member. The second member is introduced into an induction heating unit and subjected to induction heating, thereby heating the abutting portion of the second member to join the second member to the first member.

Abstract: Apparatus and method are provided for electric induction heat treatment of electrically conductive thin strip material. Multiple series-connected coil loops, each having a pole pair, are provided in each of a top and bottom induction coil, which are positioned mirror image to each other. The top and bottom induction coils form a transverse flux induction heat treatment apparatus. A separate flux concentrator is provided over and on the side of each pole. The thin strip material passes between the poles of the top and bottom induction coils and the flux concentrators associated with each of the poles.

Abstract: An annealing apparatus for annealing metallic billets, particularly for use in annealing aluminum-containing billets, comprising at least two contact elements or contact discs made of electrically conducting material, the contact elements being connected to a voltage source so as to provide electric current flow through the billet as it passes between the two contact elements. The material of the contact elements is a light metal, normally aluminum or an aluminum-containing alloy, such that the contact element material is matched to the material of the billet and diffusion of the billet material into the contact element is substantially avoided.

Abstract: A strip joining apparatus is provided wherein a time which a line is stopped is shortened, a number of installation spaces is decreased and precise notching may be performed.

Abstract: A resonance controlled conductive heating apparatus for heating a conductive load, has input terminals for receiving AC power. The primary winding of a transformer is coupled to the input terminals. First and second electrodes are coupled to the secondary winding of the transformer and are adapted respectively to electrically engage the conductive load in first and second contact points spaced from each other for direct passage of current therebetween. A resonant circuit is coupled between the secondary winding of the transformer and the electrodes. The resonant circuit has inductance, capacitance, voltage and operating frequency properties set to control a maximum current flowing across the conductive load between the electrodes.

Abstract: A wire cleaner for removing impurities from the surface of an elongated welding wire as the wire travels along a given path, the wire cleaner comprises a tunnel with a tube having a central passage surrounding the path with a gap between the tube and the wire moving through the tube, a power supply with first and second output terminals across which is generated an AC output current having a frequency in the range of about 100-300 kHz and a magnitude of at least about 1.0 amperes, a first connector attaching the first output terminal to the tube and a second terminal attaching the second output terminal to the moving wire whereby current proportional to the output current flows along the surface and across the gap to heat the wire to cause evaporation of the surface impurities. As an alternative, induction heating of the wire is used.

Abstract: A wire cleaner having a chamber and containing an arc ring for passing a wire therethrough, such that when the wire and arc ring are provided with opposite electrical potentials, an electric arc discharge occurs from the wire to the arc ring which carries off impurities from the surface of the wire. An inert gas is used to purge the chamber to prevent oxidation of the wire during and following the discharge from the wire. A pair of annular permanent magnets are positioned around the wire on each side of the arc ring to produce a magnetic field parallel to the wire which interacts with the electrical arc discharge and causes the arc to rotate around the circumferences of the wire and arc ring, thereby cleaning the entire wire. A second embodiment is provided in which the pair of permanent annular magnets is replaced by a variable strength electromagnet surrounding the arc ring and wire path. Other embodiments employ a pair of arc rings to carry the electric current so that two arcs are created in tandem.

Abstract: A wire cleaner having a chamber and containing an arc ring for passing a wire therethrough, such that when the wire and arc ring are provided with opposite electrical potentials, an electric arc discharge occurs from the wire to the arc ring which carries off impurities from the surface of the wire. An inert gas is used to purge the chamber to prevent oxidation of the wire during and following the discharge from the wire. A pair of annular permanent magnets are positioned around the wire on each side of the arc ring to produce a magnetic field parallel to the wire which interacts with the electrical arc discharge and causes the arc to rotate around the circumferences of the wire and arc ring, thereby cleaning the entire wire. A second embodiment is provided in which the pair of permanent annular magnets is replaced by a variable strength electromagnet surrounding the arc ring and wire path.

Abstract: A device for continuously heat-treating continuously cast or formed metallic goods, particularly wire and the like. The device comprises a first annealing path in which the continuously formed metallic goods are guided by means of two contact rollers. The first and second contact rollers are arranged at first and second ends, respectively, of the first annealing path. Moreover, the first and second contact rollers are connected to a voltage source such that a current flows through the continuously formed metallic goods between the first and second contact rollers. The device further comprises a second annealing path similar to the first annealing path.

Abstract: A process for manufacturing seamless flux-cored welding wires 0.8 to 4 mm in diameter with excellent cracking resistance and primer proof quality and containing very little diffusible hydrogen suited for the welding of high-tensile steels and steel structures subjected to large restraining forces by dehydrogenating by high-temperature heating comprises the steps of heating a straight wire 8 to 15 mm in diameter by direct electric heating through a first and a second pair of roll electrodes spaced 2 to 5 m apart and a ring transformer disposed therebetween to a temperature between 620.degree. and 1100.degree. C., cooling the heated wire to a temperature not higher than 500.degree. C. with a coefficient of heat transfer not higher than 250 kcal/m.sup.2 h.degree.C., and drawing to the desired diameter. The welding wire thus obtained a weld containing not more than 5 ml of diffusible hydrogen per 100 g deposited metal.

Abstract: A process and device are disclosed for regulating the annealing power in at least one annealing section of a continuous annealing and processing line for continuously cast metal products. The speed of the cast products (D) passing through the continuous annealing device is detected, as well as the voltage currently applied to the annealing section, which is converted into an effective value (U.sub.c) by means of a control device (50). The voltage supplied to the annealing section is modified by a control signal derived from the determined effective value of the voltage, in order to achieve a predetermined annealing power value dependent on the measured speed. At least the current flowing in one annealing section is also detected and converted into an effective value. The annealing power actually supplied to the annealing section is calculated from said effective values. The voltage value is modified by a control device until a predetermined value of the annealing power is reached.

Abstract: Induction heating is used to heat a moving strip (4) of non-ferrous material by causing it to form a short-circuited loop acting as the secondary winding of a transformer (1), the loop passing over pulleys (6, 9, 5 or 16). In one arrangement, one of the pulleys (16) has a double groove and the strip (4) passes over one groove (18), around another of the pulleys (19) and back to the other groove (20) of the double grooved pulley (16). This enables the strip to enter or leave the inside of the loop without colliding with the other side of the loop. In an alternative arrangement, the strip enters or leaves the inside of the loop at an angle to the plane of the loop and is prevented from contacting the other side of the loop by an insulating spacer (7).

Abstract: The present invention relates to an apparatus for continuous-direct-resistance heating of long-length articles wherein the travelling long-length article is made to contact with roll electrodes disposed in a specified spacing, then made to pass through an annular transformer disposed between the roll electrodes.Conductive members with sufficiently less electrical resistance than that of the long-length article located between the both electrodes are disposed on the periphery of the transformer with the both ends thereof connected to the roll electrode through a slider, thereby a current being induced in the long-length article with the conductive member as the retrace, which heats the long-length article having a higher resistance very efficiently, but does not result in an external voltage nor any electrical hazards along the production line in which the apparatus is installed.

Abstract: The present invention is drawn to a method and apparatus for holding wire at a specified temperature for a specified period of time by a direct-resistance heating device which applies such voltage as to generate Joule's heat in the wire, sufficient to offset the quantity of heat that would tend to be released from the heated wire during unforced cooling, after the travelling wire is heated rapidly to a specified temperature throughout its cross section.

Abstract: The copper wires employed for electrical resistance seam welding of tinned sheet metal with the help of wire electrodes until now had to be taken back to the smelter as old metal after a few applications. The additional operating costs associated with this were until now unavoidable for long seam resistance welding of tinned sheet metal since multiple uses or applications of the copper wire for resistance seam welding have proven to be impossible in spite of years of research. The problem of these additional operating costs can be solved such that new copper wires with a reduced diameter can be directly drawn from the copper wire employed as wire electrodes for resistance seam welding after their use in welding. These wires then, for example, can be used as signal conductors or as windings. The properties of these wires are totally in accord with copper wires that are directly drawn from new copper.

Abstract: A continuous process for solid-phase edge bonding a plurality of dissimilar metal strips to form a composite edge-bonded strip. A plurality of elongated metal strips of equal thickness are heated and aligned in a substantially planar, edge-to-edge relationship and pass through a pair of compression bonding rollers. The bonding roller form a rectangular-shaped cavity having a width slightly greater than the combined width of the plurality of strips and a height less than that of the strips, to reduce in thickness and further elongate the metal strips without substantially changing the combined width of the strips and to form a solid-phase bond between adjacent side edges of the strips. The strength of the solid-phase bond is substantially equal to that of the parent metal strips such that the composite strip can be cut or stamped to form detail component parts such as electronic lead frames without bond failure.

Abstract: A device installed on a traveling wire EDM apparatus for straightening the electrode wire and providing the electrode wire with a needle point end for facilitating manual threading of the electrode wire through close tolerance closed wire guide members. The device takes the form of a pair of spaced-apart current conductive metallic studs, a heat shield being located at some intermediate portion between the metallic studs. The metallic studs are connected across a source of electrical power. A length of wire proximate its end is held manually over the metallic studs, with an intermediate portion of the wire disposed within the heat shield, and a pull is manually exerted on the wire beyond the metallic studs while the wire is being heated by electrical current flow through the wire between the two metallic studs. The wire is heat-straightened and ruptures at its portion within the heat shield, with sharp needle point ends being formed at the point of rupture.

Abstract: A process for improving the core loss of magnetic materials of the type having a plurality of magnetic domains and which may have an insulative coating such as a mill glass, an applied coating, or both. The magnetic material is subjected to a local heat treatment employing radio frequency induction heating, radio frequency resistance heating, or electron beam resistance heating to induce artificial boundaries. Thereafter, the magnetic material is subjected to an annealing treatment.

Abstract: It is known to anneal non-ferrous strip material by passing the strip continuously around a pair of spaced pulleys and effecting a short circuit between the incoming and outgoing strip material to form a closed electrical loop of continuously moving strip material around the pulleys. The material in the closed moving loop is heated to anneal temperature by inserting an induction coil in the run around the pulleys so that under electrical inductive effects a current is induced in the loop thus raising its temperature. The incoming and outgoing strip material overlaps in the groove of one of the pulleys, the incoming material being fed into the loop formation at the point of overlap in a spiralling path which leads or directs the strip laterally and towards the plane of the annealing loop. Loading of the pulleys is thus made easier, arcing and sparking is avoided at overlap, and the life of the system is extended.

Abstract: Temperature monitoring of electrically conductive wire during heating in which the current in the wire in the heating zone is measured and the voltage at the downstream end portion of the zone is measured, signals corresponding to the measured values then being combined to produce a resultant signal corresponding to the resistance of the wire at the downstream end portion of the heating zone. The resistance value corresponds to the temperature of the heated wire. Apparatus includes current and voltage measuring means located in the appropriate positions to enable temperature monitoring, and means to combine voltage signals which correspond to the measured values and to produce a combined signal representative of wire resistance after heating.

Abstract: In the manufacture of tubing, and particularly finned tubing, for use by the heat transfer industry in the manufacture of heat exchangers, annealed ends and lands are desirable in certain applications to facilitate the assembly of the tubes to headers and baffles by expanding techniques. Such spot-annealed portions can be produced on a continuous basis by the described apparatus and method in which the moving tube is passed through a heating chamber which reciprocates on a carriage in the direction of tube movement. The heating chamber has a pair of power-actuated, current-carrying clamps which grip spaced portions of the tube so as to resistance-heat the tube portion between the clamps. The heating chamber and carriage move with the tube while it is clamped to provide sufficient heating time. The carriage then returns to its starting position. If desired, an inert gas can be supplied to the heating chamber to prevent oxidation and/or discoloration.

Abstract: A method and apparatus for heat treating and especially annealing of elongate metallic materials such as wire wherein the wire (24) given a longer length exposure to complete the heat treatment of the wire at higher line speeds. This is accomplished either by adding a heated storage chamber (41) holding a great length of wire (24) in sequence with conventional or modified annealing apparatus, or by substitution of a special apparatus (100) for the existing conventional annealing apparatus.

Abstract: In the manufacture of tubing, and particularly finned tubing, for use by the heat transfer industry in the manufacture of heat exchangers, annealed ends and lands are desirable in certain applications to facilitate the assembly of the tubes to headers and baffles by expanding techniques. Such spot-annealed portions can be produced on a continuous basis by the described apparatus in which the moving tube is passed through a heating chamber which reciprocates on a carriage in the direction of tube movement. The heating chamber has a pair of spaced, power-actuated clamps which grip the tubing at the ends of a discrete length portion. The heating chamber and carriage are moved with the tube while it is clamped to provide sufficient heating time to anneal the discrete length portion. The carriage then returns to its starting position. Heating of the discrete clamped tubing portion can be by a resistance technique through the clamps or by other techniques such as induction heating or gas radiant heat.

Abstract: Disclosed is an improved system for annealing strand of the type comprising at least two sheaves across which the strand passes and becomes electrically annealed, the improvement comprising a first flange member, a second flange member concentric with the first flange member and adjacent thereto, and an annealing band positioned between the first and second flange members and forming the bottom of a sheave groove, further provided that the annealing band is adapted to center strand being annealed to prevent contact between the strand and either of the flange members thereby providing a renewable, strand centering annealer sheave adapted for long life.

Abstract: An electric contact device for conveying electric current to an article such as a moving billet or wire comprising a current feeder member in a bed of electrically conductive de-oxidized metal particles and the article being placed in contact with the bed. The particles may be copper particles and the bed may be fluidized with a non-oxidizing gas and be maintained in a non-oxidizing atmosphere. Two contact devices may be provided at spaced positions to cause a current flow along the article. The contact device may operate as a switch by providing means to move the article into and out of the bed.

Abstract: An apparatus and method of continuously drawing and annealing wire in a slip mode. The method comprises the steps of directing a wire successively through a plurality of drawing dies of a continuous wire drawing machine, and from the next to the last die of the machine continuously directing the wire to and through apparatus for annealing the wire. From the annealing apparatus the wire is continuously returned to the machine for a final drawing operation. Before the wire is returned to the machine, however, the temperature of the wire is controlled to provide the wire with metallurgical properties suitable for further processing, such as the final drawing operation.

Abstract: In a method of continuously heating wire by induction, a short circuit electrical connection between wire entering a loop or loops, constituting the secondary winding of a transformer, and wire leaving the loop or loops is effcted by guiding a portion of advancing wire on to one of two pulleys, arranged on opposite sides of the transformer core, and guiding a portion of the advancing wire off this pulley in such a way that the portions of wire cross, but are not intertwined with, one another to form the loop or loops. The advancing wire entering and leaving the loop or loops is maintained under such tension that the position in space of the crossover is substantially constant and that the cross portions of the advancing wire are in continuous physical contact, the contact pressure at the position of crossover being sufficient to disturb any electrically non-conductive layers on the wire to provide clean portions for electrical contact.

Abstract: The invention relates to a process and an apparatus for the continuous heat treatment of metallic wires and bands. In the process according to the invention, the wire or band to be treated is passed around the base of the groove of a pulley and is annealed by induction heating. The treated wire or band is then cooled and re-enters the groove of the pulley above the wire or band to be treated. The invention is intended for the continuous treatment of metallic wires or bands.

Abstract: The rim of the upper sheave in a wire induction heating apparatus contains a peripheral groove. The wire passes over a portion of the groove twice, and overlaps for a certain portion. The width of the groove at a height one half the wire width from the bottom supporting surface of the groove is from one and one half to less than two times the width of the wire.

Abstract: A wire annealing apparatus of the type in which an annealing current resistively heats the wire to soften it. The annealing current is caused to flow as a result of a potential difference applied to a section of wire through low friction-free running contact pulleys. Each of the contact pulleys is as friction-free as possible because it is rotatably supported by a ball bearing on a shaft which is rotatably driven at or near the rotational speed at which the pulley is rotated by the wire. The annealing current path between the shaft and the contact pulley is completed through a low friction electrical connector assembly. Annealing current is provided from flowing through the supporting ball bearing.

Abstract: Tubes, rods, etc., are heated electrically in that current is applied via movable electrodes, one of which tracks the front and another one tracks the rear ends, but the electrodes remain spaced-apart during most of the heating.

Abstract: In apparatus for resistance-heating elongated workpieces by direct passage of current therethrough, a device for displacing the elongated workpieces longitudinally into and out of the apparatus includes rail means providing a transporting surface into and out of the apparatus, electrode carriers having rollers rollably supporting the electrode carriers on the rail means, and drive means for driving the electrode carriers along the rail means in axial direction of a respective workpiece.

Abstract: Elongated electrically-conductive workpieces such as bars, strips and wire, are resistance heated by passing an electric current through a length of the workpiece between a pair of spaced contacts. The contacts are electrically-conductive molten metal or molten salt, the molten material being continuously circulated to move it toward and into contact with the workpiece, so that it is not necessary to bend the workpiece to immerse it in a bath of molten material. The molten material is moved against the workpiece to form an extending portion of the molten material as a contact, by projecting it as a jet, pouring it as a stream, or causing it to flow over a subjacent supporting surface.

Abstract: An apparatus for controlling the electrical resistance in a moving electrical conductor during its production. The apparatus including means for conducting a current along a predetermined constant length of the thermally cured conductor, means for measuring the voltage across the predetermined length, means for comparing the voltage drop with the desired voltage drop and means for varying the extent of thermal curing of the conductor when the voltage drop measured varies from that desired. There is also provided a tension control device for the conductor in the apparatus.

Abstract: Apparatus for a continuous tandem electrical heat treating process for wire conductors for cables uses electrical contact pulleys having faces of a high melting point conductive material such as tungsten-copper. The melting point of the material is at least 1200.degree. C. The novel apparatus has reduced wear, arcing and wire breakage. Free running pulleys are also used instead of driven ones to avoid excessive tension. The free running pulleys have low torque contacts to apply high electrical current to heat the wire.

Abstract: an apparatus electrically heats a wire containing treating agents to a preselected temperature while controllably passing the heated wire into molten metal of a mold. The apparatus includes an insulated guide tube which has inlet and outlet contact orifices and wire feed apparatus for urging the wire through the guide tube at a preselected rate. A power supply is connected to the inlet and outlet contact orifices and the wire is in contact with the inlet and outlet orifices and forms an electric circuit. The circuit delivers electric current to the wire of a magnitude sufficient for increasing the temperature of the wire to a preselected temperature at the outlet orifices prior to entry of the wire into the molten metal.