Phelps Dodge Industries, Inc.

Phelps Dodge Magnet Wire Co.

Keith D Bultemeier

Jerry L Grimes

Donny R Disque

Jessie H Coon

James E Bodette

Roger D Wright

G Daniel Hilker

Verne H Lausen

George H Sollner

Richard D Remaks

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. The apparatus of the invention utilizes the flowable resin material to center the filament in a die, the size of the die controls the thickness of the coat to be applied. In the apparatus of the invention, only the resin material being applied to the filament is in contact with the filament. Thus, the mechanical wear normally associated with centering dies used in extrusion processes and like devices is completely eliminated. Further, the apparatus and method of the invention can be used to apply coats several times thinner than is possible with conventional extrusion apparatus and of materials different than those conventionally extruded onto filaments. In specific embodiments using heat softenable materials or melts, curing is no longer required; and thus, the need for curing, catalytic burners and the like as well as all concerns regarding atmospheric pollution are eliminated. The coated filaments and magnet wire made by the apparatus and in accordance with the method of the invention have coatings which are surprisingly concentric and continuous when compared to magnet wire made by conventional methods and apparatus.

Method and apparatus for manufacturing magnet wire

A novel 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 thickness 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 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. The apparatus of the invention utilizes the flowable resin material to center the filament in a die, the size of the die controls the thickness of the coat to be applied. In the apparatus of the invention, only the resin material being applied to the filament is in contact with the filament. Thus, the mechanical wear normally associated with centering dies used in extrusion processes and like devices is completely eliminated.

Apparatus for manufacturing magnet wire

An essentially linear polymer having a plurality of amide, imide and ester groups therein, which is the condensation product of (1) at least one polycarboxylic acid five member ring forming reactant, (2) at least one ethylenically unsaturated polycarboxylic acid five or six member lactam ring forming reactant, (3) at least one polyfunctional amino five or six member ring forming reactant, (4) at least one glycol, (5) at least one other polyfunctional hydroxyl compound, and (6) at least one other carboxylic acid ester reactant chosen from the group consisting of the acids, esters, anhydrides, and akylesters of terephthalic, isophthalic, and benzophenone dicarboxylic acids. The molar ratio of the functional hydroxyl groups of said glycol and hydroxyl compound to the functional ester forming carboxyl groups of said acid reactants is greater than about 1.3 to 1. The molar ratio of the functional imide-forming groups of said polycarboxylic acid five member ring forming reactant and said polyfunctional amino reactant to the functional lactam-forming groups of said ethylenically unsaturated acid reactant and said polyfunctional amino reactant are greater than about 0.5 to 1 and less than about 3.0 to 1. The molar ratio of said functional ester forming carboxyl groups to said functional imide-forming and lactam-forming groups are greater than about 1.0 to 1 and less than about 3.0 to 1. The method of forming said polymer includes placing the reactants in a solvent of the polymer having a boiling point in excess of about 150.degree. C. such as cresylic acid, heating the reactants and solvent at atmospheric pressure from about 120.degree. C. to about 220.degree. C., adding a suitable condensation catalyst after a reaction commences, and diluting or cooling resulting polymer solution to terminate the reaction.

Essentially linear polymer having a plurality of amide, imide, and ester

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Fort Wayne, IN, United States of America

Keith D Bultemeier