Process for manufacturing coated wire composite and a corona generating

Abstract

An improved process for manufacturing glass coated wire, for example, a corona generating electrode having a dielectric coating layer of the type used in electrostatographic printing applications, wherein predetermined stresses are induced along the axial, radial, and hoop stress vectors present in the dielectric coating. In accordance with the present invention, there is provided a process for manufacturing a coated wire composite including a core wire having a coating layer of dielectric material thereon, comprising the steps of: providing a preform of dielectric coating material in a cylindrically tubular shape defining an inside diameter and an outside diameter and having a predetermined length; aligning a continuous length of the core wire with the inside diameter of the preform for transporting the wire therethrough in a coaxial arrangement such that the wire enters the preform at an entrance orifice and exits the preform at an exit orifice; applying heat to the preform for melting a portion of the preform in the proximity to the exit orifice for providing molten dielectric material in contact with the core wire such that a portion of the molten dielectric material is caused to collapse onto and bond to the core wire; and cooling the molten dielectric material on the core wire to resolidify the dielectric material to form the coated wire composite including a core wire having a coating layer of dielectric material. An additional process parameter for inducing selected radial and hoop stresses in the coating layer is also disclosed.