Abstract: A method for forming an EDM wire electrode includes coating a copper wire core with zinc, and then heating the coated wire in an oxidizing atmosphere to simultaneously provide a copper-zinc alloy layer over the copper core and a zinc oxide surface on the alloy layer. The oxide- and alloy-coated wire is then reduced in diameter to reduce the thickness of the alloy layer by about one-half of its initial thickness. The resulting electrodes wire permits a greater current density and a greater tractional force to be employed, yielding a significantly greater machining speed in the EDM process.

Abstract: A system and a method for converging and filling unfilled small unit cables into a single large cable in a single pass at a single station is disclosed. The single pass filling station comprises a pressure chamber in which the unfilled small pair count unit cables are filled with filling compound and the plurality of unit cables are converged into a single cable as the converged cable enters into a pressure tube where additional filling compound at at least slightly higher pressure is applied thereto. The assembled and filled large cable is then wiped of excess filling compound, wrapped, bound and collected on a take up reel.

Abstract: A superconductive substance is formed into fine wires readily without producing surface defects on the wires and correctly with a predetermined even diametric thickness. Highly refractory metallic core is heated to a predetermined temperature higher than the eutectic point of powders which constitute the superconductive substance, and passed through said powders whereby the powders which make contact with the core melt and adhere to the core with a predetermined uniform thickness, forming a fine wire made from the superconductive substance.

Abstract: A method of making a cable article which comprises a conductor that is at least partially insulated by a flexible composition, said method comprising forming a homogeneous, interdispersed polymer insulation composition by combining low density polyethylene polymer with a polychloroprene polymer and at least an amount of fibrous polytetrafluoroethylene that is effective to form an interdispersion of polymers and thereafter coating a conductor with said insulating composition.

Abstract: Wire for repairing or changing circuit elements such as printed circuits, has heat-resistant insulation surrounded by a hot-melt adhesive. The wire is attached to the surface of printed circuit boards easily by applying a hot iron to the adhesive layer on the wire and melting the adhesive which then adheres to the board surface. The coating is applied by passing insulated wire vertically through a length of molten adhesive and then through a die. Printed circuit board modifications can be made quickly and easily and at a relatively low cost.

Abstract: A method and apparatus for the application of moisture blocking compound to the interstitial spaces of a stranded conductor. The application of the compound is accomplished through the use of a cone die which regulates the amount of compound applied to the conductor.

Abstract: A method of manufacturing a flexible electric cable constituted by a polymer-coated stranded conductor made up of fine strands of aluminum or aluminum alloy having a diameter of less than 0.5 mm, or constituted by one or more insulated conductors surrounded by an electric screen itself constituted by fine strands of aluminum or aluminum alloy having a diameter of less than 0.5 mm and wrapped or braided about the conductor(s). The screen is surrounded by at least one insulating layer of polymer material, wherein the operation of stranding together the fine strands forming the conductor or of wrapping or braiding the strands surrounding the insulated conductor(s) and forming the electric screen is performed by using fine strands which are not annealed or which are only partially annealed, with the stranded conductor or the wrapped or braided electric screen then being covered with insulation and subjected to at least one final annealing operation.

Abstract: Method of making insulated conductor wire in which a homogeneous mixture of a dielectric carrier and magnetically permeable particles is sprayed onto the wire to deposit a layer of the mixture on the wire. The layer is then hardened to provide an insulating layer with the particles substantially uniformly dispersed therein.

Abstract: A dark heater is produced by a method which comprises coating the first coating layer made of an insulating material with a suspension containing heat-resistant particles having a high thermal emissivity, such as W particles, while 0.5 to 1.5 wt. % of a volatile matter such as water remains in the first coating layer to form a dark coating layer. Since the suspension having a low viscosity can be used, the thickness of the dark coating layer can be made highly uniform and the emission characteristics of the heater can be stabilized.

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 novel method and apparatus for manufacturing magnet wire in a continuous process by which coatings of a flowable resin material may be applied concentrically to a moving elongated filament in thicknesses of about 16 mils or less. The filament can be a bare copper or aluminum conductor having round or rectangular configuration or an insulated conductor upon which a top or an intermediate coat of material is desirably applied. Coatings of one-half mil and one mil also can be applied by the method of the invention. By the method and apparatus of the invention, magnet wire can be manufactured by continuously drawing the wire to size, annealing the wire, if necessary, insulating the wire with one or more coats of flowable resin material, curing the resin material, if necessary, hardening the resin material, and spooling the wire for shipment, without interruption at speeds limited only by the filament pay-off and take-up devices used.

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 method for protecting heat sensitive substrates from fire and excessive heat involves:I. applying to the substrate a layer of a char forming intumescent curable composition comprising:(a) an epoxide group containing material, at least 20 weight percent of said material having an oxirane functionality greater than 2;(b) a curing agent adapted to cure the epoxide group containing material wherein at least 20 weight percent of said curing agent is comprised of an aralkyl polyamine containing material;(c) an additive component comprising a mixture of materials adapted to provide a source of:(i) phosphorous,(ii) zinc,(iii) boron and(iv) an expansion gas upon thermal decomposition,said curable composition being capable of forming a carbonaceous char upon exposure to heat or flame;II. allowing the intumescent curable composition to at least partially cure.

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: An electrostatic filament coater comprising a plurality of coating chambers arranged coaxially in spaced apart serial relation. Each of the coating chambers has a base and an apex and being generally frusto-conical in shape with an exit opening at the apex and an entrance opening at the base. All of the coating chambers except the last one are positioned with the apex being within the base of the next adjacent coating chamber. The filament is trained through the coating chambers. A plurality of electrodes are positioned within the coating chambers so as to surround the filament. A near arc-over voltage is supplied to the electrodes and a fog of particulate coating material suspended in a gas is passed through the coating chambers and axially of the filament at a velocity which results in the electrostatic deposition of the particulate matter on the filament and the exhaust of the gas and excess particulate matter from between the coating chambers and the apex opening of the last coating chamber.

Abstract: A novel curable rubber composition is described which is curable at low temperatures.

Abstract: The surface of an aluminum conductor is roughened, for example, by blasting. A hydrophilic film such as a boehmite film, an anodic oxide film and a chemical conversion film is formed on the roughened surface. A protective film made of a wetting agent or a hydrophilic resin is formed on the hydrophilic film. The conductor may comprise a compressed aluminum conductor.

Abstract: Method of making copper clad conductor by impinging of copper particles upon a heated steel wire to cause adhesion of the particles to the wire, by coalescence, building up the particles to form a coating and then drawing the coated wire to the required diameter. The coated wire may be heat treated to cause flow of copper to improve the surface finish before the drawing process. The copper particles may be directed at the wire by a spraying technique. Alternatively, the wire is passed over a fluidized bed of the particles and through a cloud of particles thrown up by the bed.

Abstract: A length of braided wire, having an outside diameter, is selected as is a length of heat-shrinkable tubing which has an initial inside diameter greater than the outer diameter of the braided wire. The braided wire is inserted into the tubing such that, at one end of the tubing, the tubing extends beyond the braided wire. The one end of the tubing is grasped without grasping the braided wire, and the one end is supported against movement in a vertical direction. A weight is attached to the other end of the tubing so that the tubing with the braided wire inserted will extend downwardly from the first end to the other end thereof. Heat is applied to the tubing starting at the one end and moving slowly downwardly to the other end. The heat causes the tubing to shrink and, simultaneously, the weight pulls the tubing downwardly to cause the tubing to stretch so that a tight-fitting insulating cover, having decreased wall thickness, is produced.

Abstract: A fire retardant polymeric compound comprises a polymer having hydroxyl groups and an inorganic phophate so as to produce a char by the process of intumescence when subjected to combustion. The polymer may be an ethylene vinyl alcohol copolymer and the inorganic phosphate may be ammonium polyphosphate.

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 a magnet wire enamel to a magnet wire substrate and additionally disclosed is a method for making such magnet wire enamel.

Abstract: In the method, the radio frequency (RF) antenna is made by providing a clean coil made of copper tubing or other metal conductor, which is coated with a tacky organic binder, and then with a powdered glass frit, as by sprinkling the frit uniformly over the binder. The coil is then heated internally in an inert gas atmosphere, preferably by passing an electrical heating current along the coil. Initially, the coil is internally heated to about 200.degree. C. to boil off the water from the binder, and then to about 750.degree. C.-850.degree. C. to melt the glass frit, while also burning off the organic binder. The melted frit forms a molten glass coating on the metal coil, which is then cooled to solidify the glass, so that the metal coil is covered with a thin continuous homogeneous impervious glass coating of substantially uniform thickness.

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: In a method and apparatus for coloring polymer-insulated wire, the wire is guided through a solvent reservoir to dissolve surface contaminants and etch the surface of the insulation, and passed between opposed wiping surfaces to wipe surface contaminants from the wire. The wire is then passed through a hot air duct to evaporate solvent remaining on its surface. The dried wire is guided through a solvent-based colorant reservoir to coat it with colorant and passed against a wiping surface to wipe excess colorant from its surface. The coated wire is passed through a hot air duct to evaporate some of the solvent in the colorant, and through a cold air duct to harden an outer surface of the colorant before it passes over a guide wheel. The hardened surface prevents adherence of the colorant to the guide wheel. The coated wire is passed by a spraying device which intermittently sprays solvent-based colorant on the wire to band encode it.

Abstract: A method of and apparatus for making the cable core of a telecommunication cable water-tight in the longitudinal direction, in which a filling material having a base of petroleum jelly is heated to a temperature above the drop point, is supplied under pressure to a filling head (5), is divided into a number of jets distributed over the circumference of the cable core, is passed through the filling head (5) with simultaneous conversion of the static pressure into kinetic energy and is injected through the outer layer of the cable core into the heart of the cable core, in which a reconversion of the kinetic energy into static pressure is effected and all the interstices and gaps between the single wires of the cable core are filled with the filling material.

Abstract: A method for making an electrical inductive device for use in hermetic atmospheres which incorporate refrigerants such as halogenated methane compositions, for example refrigerant R-22, monochlorodifluoromethane. The device may be a wound coil device formed of magnet wire, the enamel coating of which has resistance to blistering when exposed to refrigerants under saturated conditions at temperatures up to about 200.degree. or 210.degree. C. and above. The enamel coating composition or wire enamel is formed as the reaction product of 1,2,3,4-butanetetracarboxylic dianhydride, optionally with an aromatic dianhydride, and a diamine such as p,p'-methylenedianiline or p,p'-oxydianiline, in an organic solvent such as N-methyl-2-pyrrolidone.

Abstract: A crosslinking process wherein at a temperature of about 10.degree. to 160.degree. C., under a pressure of about 1 to 300 bars and for at least about 0.5 hour, a polymer, containing from about 42 to 99% by weight of units derived from ethylene and, where appropriate, also from an .alpha.-olefin, from about 1 to 8% by weight of units derived from maleic anhydride and from 0 to about 50% by weight of units derived from at least one additional monomer selected from an ester of an unsaturated carboxylic acid with an alcohol containing from 1 to 12 carbon atoms, is reacted with at least one polyepoxide compound, preferably present in an amount of from about 1 to 10 parts by weight, based on 100 parts by weight of the polymer, in the presence of at least one catalyst suitable for reacting the anhydride functions with the epoxide functions. The catalyst is preferably present in an amount from about 0.02 to 2 parts by weight, based on 100 parts by weight of the polymer.

Abstract: A magnet wire enamel having improved runnability and insulating properties is described comprising nylon containing 0.5% to 3.5% by weight tetraalkyl titanate. The nylon can be a sole coat, outermost coating, or bond coat.

Abstract: A magnet wire enamel having improved runnability and insulating properties is described comprising nylon containing a titanate selected from the group consisting of (RO).sub.4 Ti, dimers, trimers, and mixtures thereof where R is an aromatic group. The nylon can be a sole coat, outermost coating, or bond coat.

Abstract: An electron beam curable magnet wire enamel comprises the reaction product of a polyester prepolymer having terminal functional groups reactive with an isocyanate, and a urethane-acrylate prepolymer formed by reacting a diisocyanate and a hydroxyalkylacrylate. The resulting polymer is extrudable at 100% solids onto a magnet wire substrate and electron beam curable.

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.

Abstract: The purpose of the invention is to manufacture varnish-bonded thread-covered circular-section and profile-section wires and braided conductors in a manner which is particularly cheap and which involves particularly little risk of contaminating the environment.Suitable thread-covered wires and braided conductors are obtained by impregnation, in one operation, with partially crystalline or amorphous thermoplastic polycondensates.

Abstract: Wire which has been coated with a polymeric material is useful in a wide variety of applications. One such application is as a winding for electrical equipment such as motors, transformers, magnetic coils, relays and the like. Generally, coated wires of this type have been prepared by coating the wire with multiple layers of a solution of the coating material. It has been determined that metal wires can be satisfactorily coated with a specific type of thermoplastic composition in a single layer without using solvents. This process utilizes a tubing type cross-head die with the thermoplastic composition comprising a mixture of 80% to 99% by weight polyethylene terephthalate and from 1% to 20% by weight of polyethylene, polypropylene, or a mixture thereof.

Abstract: In providing a dried insulation layer upon conductor, a covering fluid layer is initially provided by a process and apparatus in which the layer is formed from composite material comprising magnetically permeable particles homogeneously mixed with a fluid carrier. The fluid layer is formed by passing the conductor through a reservoir of the material and then vertically through a die orifice. The reservoir of fluid applies pressure at the die orifice and this pressure is adjustable to vary the rate at which the material passes through the orifice and thus varies the diameter. This pressure is controllable by adjusting the height of the reservoir above a die orifice or by adjusting gas pressure acting downwardly upon the material. The diameter of the layer is advantageously measured after it is dried and variation in measured diameter from that desired effects a change in pressure to alter the diameter towards that desired. The diameter of the layer may, however, be measured with the layer in fluid form.

Abstract: A method of protecting electrical or electronic circuitry by embedding said circuitry in a low molecular weight ethylene-alpha-olefin copolymer composition.

Abstract: The structure and process for providing a sealed insulated piping arrangement by introducing a molten sealing material between the inner fluid conducting pipe, and an outer casing, which space may include monitoring wires. The sealing material is introduced in a molten state to provide a liquid-impermeable filling, and then providing an enclosing seal at the end with a smooth transition for passage of the monitoring wires.

Abstract: A method and apparatus for coating telephone cable or other continuous lengths of cylindrical objects with a continuous coating of molten thermoplastic sealant material. The cable or cylindrical object is passed through an annular array of nozzles operative to apply multiple beads of molten thermoplastic material to the surface of the cable or object. A liquid impervious casing is then placed over the bead coated cable while the beads are still in a molten state. The casing compresses the beads and forms them into a continuous coating of thermoplastic material surrounding the cable or object and contained within the liquid impervious casing.

Abstract: Making an insulated electrical conductor having an insulation layer formed from dielectric carrier with magnetically permeable particles dispersed therein in which the conductor bearing the layer is passed through a magnetic field to cause an increase in magnetization of magnetic domains of the particles towards a single direction.

Abstract: A magnet wire enamel having improved runnability and insulating properties is described comprising nylon containing 0.25% to 20% by weight titanium chelate. The nylon can be a sole coat, outermost coating, or bond coat.

Abstract: A method of manufacturing an insulant having a self reticulating structure for an electrical cable including at least one bare wire (1) obtained from a wire-drawing machine (10), the method comprising:using grafted polyethylene which is finely crushed or which is obtained in powder form;finely crushing gypsum to act as an expansion agent and as a reticulation catalyst;mixing the polyethylene and the gypsum without kneading; andmaking a fluidized bed or an electrostatic suspension of the resulting mixture and passing a bare wire through the resulting fluidized or suspended mixture while the wire is at high temperature at the outlet from the wire-drawing machine, the temperature being in the range 200.degree. C. to 350.degree. C.

Abstract: A method for manufacturing a flame-retardant insulated wire and cable for use in nuclear power stations, comprises the steps of: extruding on a conductor or cable care to a predetermined thickness a composition consisting of 100 parts by weight of a basic polymer such as a thermoplastic resin or a rubber which can be crosslinked by an organic peroxide-based crosslinking agent, at least 10 parts by weight of a halogenated acenaphthylene or a condensate thereof, and 0.5 to 10 parts by weight of an organic peroxide; and heating a resultant wire or cable for crosslinking in the absence of water and at a temperature higher than the decomposition temperature of the organic peroxide.

Abstract: A corona-resistant wire enamel composition is described comprising a polyetherimide resin and from about 1% to about 35% by weight of dispersed alumina particles of a finite size less than about 0.1 micron, the alumina particles being dispersed therein by high shear mixing. A method of providing corona resistant insulations for an electrical conductor employing the above composition and an electrical conductor insulated with a coating of the wire enamel composition are also disclosed.

Abstract: A priorly used drop wire having a single layer of PVC insulating compound, containing a relatively-expensive epoxy additive, extruded over a spaced pair of conductors, having relatively rough surfaces, is replaced with drop wire having less-costly, relatively-smooth, drawn, conductors onto which spaced, unplasticized particles of PVC resin are coated and the portions of the particles contacting the surfaces of the conductors are melted, caused to undergo controlled degradation and adhere to the surface of the conductor, and thus form a relatively-stable, texturized, discontinuous coating of adhesion sites on the surfaces of the conductors with interdispersed portions of the surfaces being exposed.Over the precoated conductors, a composition containing a plasticized PVC resin may be extruded to form an insulating covering having a relatively-stable, controlled-degree of adhesion to the adhesion sites and the interdispersed, exposed surfaces of the conductors.

Abstract: A composite cathode active material/current collector product useable as a component of a cathode for secondary batteries without the need for a separate current collector, which comprises a wire having a conductive interior portion of a transition metal and an exterior portion of an intercalatable layered transition metal chalcogenide, is made by a method which involves reacting a transition metal wire with a vapor of a chalcogen or a hydrogen chalcogenide.

Abstract: A corona-resistant wire enamel composition is described comprising a polyimide, polyamide, polyester, polyamideimide, polyesterimide, or polyetherimide resin and from about 1% to about 35% by weight of dispersed alumina particles of a finite size less than about 0.1 micron, the alumina particles being dispersed therein by high shear mixing. A method of providing corona resistant one and two-stage insulations for an electrical conductor employing the above compositions and an electrical conductor insulated with a one or two-stage coating of the wire enamel compositions are also disclosed.

Abstract: A coil comprising a carbon filament winding with fused particulate insulative coating therearound and method of producing such carbon filament coil.

Abstract: A method of making insulated wires or cables in which a tube of crystallizable polymeric material is first extruded over size on the wire, cooled until it can be gripped and then reheated and stretched to produce crystalline orientation and to collapse it into contact with the wire is distinguished by first holding the tube at a temperature between its glass transition temperature and its crystalline melting point long enough for the degree of crystallinity to be significantly increased. Physical properties after orientation are considerably improved.

Abstract: Providing an electrical conductor with an insulation layer having a layer of dielectric carrier with magnetically permeable particles dispersed within the carrier, in which homogeneity is maintained in a fluid mixture of a fluid carrier and the particles, the conductor is moved vertically through a die means to coat it with a fluid layer of the mixture, the fluid carrier is dried and thickness of the dried insulation layer is controlled. This control is achieved by monitoring the thickness or diameter of the dried layer and, if a variation exists between the monitored and required values, the rate of fluid flow through the die means is adjusted to adjust the monitored values towards that required.

Abstract: An apparatus and method for extruding a thin uniform coating of fluent plastic material about a continuously advancing strand wherein the fluent plastic material is directed radially toward the strand through a constricted annular feed passage. The strand with the fluent plastic material adhering thereto is then advanced through a passageway conically converging to an exit end and effective to develop hydrodynamic pressure forces which center the strand within the passageway.