A continuous preparation apparatus and method for bare metal wires

Abstract

This invention discloses a continuous preparation apparatus for bare metal wires, comprising a feeding mechanism for providing glass-clad wires, a peeling mechanism for removing the outer glass layer from the glass-clad wires, a cleaning mechanism, a winding mechanism for winding the inner alloy wire of the glass-clad wires, and a control system used in conjunction with the winding mechanism. The peeling mechanism includes a frame and a rotary roller mounted on the frame, the rotary roller being used to wind the glass-clad wires to form a rotary transport direction. This invention also provides a continuous preparation method. The apparatus provided by this invention can achieve the continuous preparation of ultrafine bare metal wires with a length greater than 1000 meters and a diameter of 20-60 micrometers.

Description

Technical Field

[0001] This invention belongs to the field of preparation of bare metal wire with circular cross-section, and specifically relates to a continuous preparation apparatus and method for bare metal wire. Background Technology

[0002] Micron-sized ultrafine metal wires, with their extremely small diameter and excellent mechanical and electromagnetic properties, are widely used in fields such as communication technology, electronic power, new energy vehicles, biomedicine, and national defense. For example, micron-sized gold-silver based bonding wires are widely used in the packaging and pin connection of microelectronic components and semiconductor chips due to their good conductivity and heat dissipation. Ferromagnetic CoFe based alloy wires are widely used in many key fields such as target detection and tracking, non-destructive testing, and biomagnetic field measurement due to their excellent soft magnetic properties, high permeability, and excellent magnetic sensitivity. In addition, ultrafine titanium-based wires, due to their good shape memory function and mechanical properties, can be used as structural materials in products such as tension members, drive shafts, and textile reinforcing fibers.

[0003] Currently, micron-sized ultrafine metal wires are mainly prepared through two methods: multi-pass drawing of alloy rods and rapid quenching of molten alloys. Relatively speaking, drawing suffers from cumbersome processes, short continuous production lengths, and die wear. Rapid quenching of molten alloys is mainly divided into melt drawing, internal hydrospinning, and glass coating. Internal hydrospinning and melt drawing can directly produce bare metal wires, but the resulting wires have large diameters and still require drawing. Furthermore, their processes limit the length of the produced wires, making them unsuitable for continuous batch processing. Currently, only glass coating can achieve continuous production of 1000-10000m-scale ultrafine metal wires. In most applications, metal wires are generally used as conductive media in circuits; however, the glass layer on the surface of glass-coated wires significantly affects their conductivity, limiting their application. Therefore, to meet the needs of industrial production and application, the surface glass layer of glass-coated wires can be removed to obtain ultrafine bare metal wires.

[0004] Currently, the glass layer on the surface of glass-coated wire is mostly removed by etching with hydrofluoric acid or similar methods. For example, patent CN116179815A removes the glass layer using a mixed etching solution composed of hydrofluoric acid, sodium thiocyanate, and hexamethylenetetramine. However, this etching method typically suffers from uncontrollable etching time, short lengths of bare wire, easy corrosion damage to the metal wire itself, and environmental and health hazards from the etching solution. Patent CN107900297A uses a flat plate to apply pressure to crush and remove the glass layer from the surface of the glass-coated wire. While this mechanical method is more controllable than etching, less likely to damage the metal wire, and more environmentally and human-friendly, it remains inefficient and struggles to achieve continuous removal of the glass layer. Furthermore, patent CN117655887A discloses a method and equipment for removing the glass layer by grinding with an abrasive wheel, which can efficiently achieve continuous removal of the glass layer and winding of the bare metal wire. However, the grinding with the abrasive wheel can cause scratches on the surface of the metal wire. Summary of the Invention

[0005] The purpose of this invention is to provide a continuous preparation apparatus and method for bare metal wires, which can achieve the task of continuously preparing ultrafine bare metal wires with a length of more than 1000 meters and a diameter of 20-60 micrometers.

[0006] To achieve the first objective of this invention, the following technical solution is provided: a continuous preparation apparatus for bare metal wire, comprising a wire feeding mechanism for providing glass-coated wire, a peeling mechanism for removing the outer glass layer of the glass-coated wire, a cleaning mechanism, a winding mechanism for winding the inner alloy wire of the glass-coated wire, and a control system used in conjunction with the winding mechanism.

[0007] The peeling mechanism includes a frame and a rotary roller mounted on the frame. The rotary roller is used for winding glass coating filaments to form a rotary conveying direction.

[0008] The cleaning mechanism is used to remove glass fragments adhering to the alloy wire core of the winding glass-coated filament.

[0009] The control system includes a diameter detection component installed at the winding inlet of the winding mechanism, and a control circuit. The control circuit adjusts the winding speed of the winding mechanism or replaces rotary rollers of different diameters by comparing the detection result of the diameter detection component with the diameter required by the preset process.

[0010] The device provided by this invention utilizes the difference in toughness / brittleness between the inner alloy wire and the surface glass layer of the glass-coated filament. Peeling is achieved by rotating the raw material around a rotary roller. During rotational winding, the inner alloy wire exhibits good toughness and will not break, while the surface glass layer is brittle and broken off. Furthermore, the peeling effect can be controlled by selecting rotary rollers of different diameters, and the winding speed can be controlled to ensure that the cleaning mechanism can fully remove residual glass fragments from the surface, thereby comprehensively controlling and improving peeling efficiency and quality.

[0011] Specifically, the wire feeding mechanism includes a feeding shaft for mounting the wire roll and an axial end cap that cooperates with the feeding shaft, the axial end cap being used to restrict axial sliding of the wire roll.

[0012] Specifically, the peeling mechanism also includes a support cover disposed outside the frame, which is used to support the rotary roller, prevent glass fragments from splashing, and collect glass fragments in a concentrated manner.

[0013] Specifically, the diameter of the rotary roller is 2 to 6 times the diameter of the input glass coating filament, and can be replaced as needed. If the diameter is too small, the rigidity and strength of the rotary roller will decrease, and it will be easily damaged; if it is too large, the peeling effect will be poor.

[0014] Specifically, the winding speed of the winding mechanism is in the range of 0.1m / min to 10m / min. That is, if the winding speed is too slow, the efficiency will be low, and if the winding speed is too fast, the wire will easily break.

[0015] Specifically, the cleaning mechanism includes an ultrasonic cleaner with a cleaning tank, and a guide wheel disposed in the cleaning tank to guide the glass-coating filaments into the cleaning tank in order to remove residual glass fragments.

[0016] Specifically, the rotary roller is made of a high-hardness, high-rigidity and wear-resistant metal rod to ensure stable force during the process of peeling the surface glass of the glass coating wire.

[0017] Specifically, the metal rod is selected from molybdenum rods or tungsten rods.

[0018] To achieve the second objective of this invention, the following technical solution is provided: a continuous preparation method, implemented using the aforementioned continuous preparation apparatus for bare metal wires, comprising the following steps:

[0019] The roll of material with unprocessed glass-coated filaments is placed on the feeding shaft and axially fixed by the axial end cap;

[0020] The unprocessed glass-coated filaments on the roll are extracted and passed sequentially through the peeling and cleaning mechanisms until they reach the winding mechanism.

[0021] Test start the equipment to ensure that the peeling mechanism, cleaning mechanism, and diameter detection component are operating normally, and that the glass covering wire is running normally;

[0022] Adjust the winding speed or replace the rotary roller with one of different diameters based on the detection results of the diameter detection component until a glass-coated filament core alloy wire with the same preset diameter is obtained.

[0023] Specifically, based on the detection results from the diameter detection component, the winding speed is adjusted or a rotary roller of different diameter is replaced. The actual diameter measured in the detection results is compared with the preset diameter to perform coarse and fine adjustments to the device.

[0024] If the test results show that the diameter of a local area is larger than the diameter of the preset glass-coated filament core alloy wire, then the diameter of the rotary roller will be replaced with one-fifth of the current diameter of the rotary roller.

[0025] If the test results show that a local diameter is larger than the preset diameter of the glass-coated filament core alloy wire, the diameter of the rotary roller is gradually replaced with two-thirds of the current rotary roller diameter until a glass-coated filament core alloy wire with the same preset diameter is obtained.

[0026] If the diameter of the replaced rotary roller is less than twice the diameter of the glass-coated filament, then the winding speed is adjusted: when the test results show that the diameter of some parts is greater than the diameter of the preset glass-coated filament core alloy wire, the winding speed is adjusted to half of the current winding speed. If the diameter of some parts is still greater than the diameter of the preset glass-coated filament core alloy wire, then the diameter of the rotary roller is gradually replaced with two-thirds of the current rotary roller diameter.

[0027] If the test results show that a local diameter is discontinuously larger than the preset diameter of the glass-coated filament core alloy wire, the winding speed is adjusted to four-fifths of the current speed. This adjustment is repeated until a glass-coated filament core alloy wire with the same preset diameter is obtained.

[0028] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0029] Based on the physical properties of glass-coated filaments, a corresponding peeling mechanism was designed to overcome the current problem of not being able to continuously produce ultrafine bare metal filaments with a length greater than 1000 meters and a diameter of 20-60 micrometers. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the continuous preparation apparatus for bare metal wires provided in this embodiment;

[0031] Figure 2 This is a demonstration diagram of the peeling state of the glass-coated filaments provided in this embodiment;

[0032] Figure 3This is a three-dimensional schematic diagram of the peeling mechanism provided in this embodiment;

[0033] Figure 4 This is a comparison chart of the peeling effects of rotary rollers with different diameters provided in this embodiment;

[0034] In the diagram, 1. Material roll; 2. Feeding shaft; 3. Peeling mechanism; 4. First guide roller; 5. Second guide roller; 6. Ultrasonic cleaner; 7. Third guide roller; 8. Fourth guide roller; 9. Fifth guide roller; 10. Diameter detection assembly; 11. Rewinding shaft; 12. Rewinding wheel; 13. Bearing; 14. Rotary roller; 15. Frame; 16. Inner core alloy wire; 17. Surface glass layer; 18. Support cover. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0036] like Figure 1 As shown, the continuous preparation apparatus for bare metal wire provided in this embodiment includes a wire feeding mechanism for providing glass-coated wire, a peeling mechanism 3 for removing the outer glass layer of the glass-coated wire, a cleaning mechanism for removing residual glass fragments, a winding mechanism for winding the inner alloy wire of the glass-coated wire, and a control system used in conjunction with the winding mechanism.

[0037] The glass-coated filament is guided by the first guide wheel 4, the second guide wheel 5, the third guide wheel 7, the fourth guide wheel 8, and the fifth guide wheel 9 to complete the peeling and winding tasks.

[0038] The wire feeding mechanism includes a feeding shaft 2 for mounting the material roll 1, and an axial end cap that cooperates with the feeding shaft 2 to restrict axial sliding of the material roll 1.

[0039] The winding mechanism includes a winding shaft 11 connected to an output motor, and a winding wheel 12 fixed on the winding shaft 11. The circumferential surface of the winding wheel 12 is made of silicone to prevent slippage when winding the product.

[0040] The cleaning mechanism includes an ultrasonic cleaner 6 with a cleaning tank and guide wheels, which include a third guide wheel 7 and a fourth guide wheel 8. The rotational connecting line of the third guide wheel 7 and the fourth guide wheel 8 is parallel to the bottom of the cleaning tank to ensure that the glass-coated wire is thoroughly cleaned.

[0041] The control system includes a diameter detection component 10 installed at the winding inlet of the winding mechanism, and a control circuit. The control circuit adjusts the winding speed of the winding mechanism by comparing the detection result of the diameter detection component 10 with the diameter required by the preset process. The diameter detection component selected in this embodiment mainly measures the diameter of the bare metal wire in real time, and the peeling effect can be directly judged by the diameter of the metal wire after peeling and cleaning.

[0042] like Figure 2 The diagram shown is a demonstration of the glass-coated filament peeling process provided in this embodiment. The device provided in this embodiment utilizes the difference in toughness / brittleness between the inner alloy wire 16 and the surface glass layer 17 of the glass-coated filament to achieve peeling by rotating the raw material around the rotary roller 14. During the rotational winding, the inner alloy wire 16 has good toughness and will not break; while the surface glass layer 17 will be broken and removed due to brittle fracture.

[0043] like Figure 3 The diagram shown is a three-dimensional schematic of the peeling mechanism provided in this embodiment, including a frame 15 and a support cover 18 fixed on the frame. The support cover 18 is connected to a rotary roller 14 via a bearing 13. The rotary roller 14 is used to wind the glass coating wire and form a rotary transmission; the bearing 13 reduces the rotational damping of the rotary roller 14, allowing the rotary roller 14 to rotate together with the glass coating wire wound on it, preventing it from breaking the glass coating wire during the peeling process; the support cover 18 supports the rotary roller 14 and prevents glass fragments from splashing during peeling.

[0044] More specifically, the rotary roller 14 provided in this embodiment is made of molybdenum rod, and its diameter is 2 to 6 times the diameter of the input glass-coating wire. If the diameter is too small, the rigidity and strength of the rotary roller decrease, making it easily damaged; if it is too large, the peeling effect is poor. To better illustrate the influence of the diameter provided in this embodiment on the peeling effect, the diameter of the glass-coating wire in the test was designed to be approximately 65 μm, with the inner alloy wire diameter being approximately 40 μm. Two molybdenum rods of the same material but with diameters of 325 μm and 500 μm respectively were selected, and their peeling effects were as follows: Figure 4 As shown, Figure 4 The red line represents the diameter of the glass-coated wire core alloy wire after the 325μm diameter molybdenum rod has been peeled. Figure 4 The blue line represents the diameter of the glass-coated wire core alloy wire after the 500μm diameter molybdenum rod has been peeled. Figure 4 The diameter of the unpeeled glass-coated filament in the middle black line section;

[0045] As shown in the figure, selecting a rotary roller within the corresponding range for the diameter of the unpeeled glass-coated filaments can effectively improve the peeling effect.

[0046] Meanwhile, the winding speed of the winding mechanism proposed in this embodiment is 0.2 m / min.

[0047] This embodiment also provides a continuous preparation method, which is implemented using the continuous preparation apparatus for bare metal wires provided in the above embodiment, and the steps include the following:

[0048] The roll of material with unprocessed glass-coated filaments is placed on the feeding shaft and axially fixed by the axial end cap;

[0049] The unprocessed glass-coated filaments on the roll are extracted and passed sequentially through the peeling and cleaning mechanisms until they reach the winding mechanism.

[0050] Test start the equipment to ensure that the peeling mechanism, cleaning mechanism, and diameter detection component are operating normally, and that the glass covering wire is running normally;

[0051] Based on the detection results from the diameter detection component, the winding speed is adjusted or rotary rollers of different diameters are replaced until a glass-coated filament core alloy wire with the same preset diameter is obtained. The process mainly involves comparing the diameter in the current detection results with the preset diameter, and adjusting various design parameters in the device through coarse and fine adjustments.

[0052] If the test results show that the diameter of a local area is larger than the diameter of the preset glass-coated filament core alloy wire, then the diameter of the rotary roller will be replaced with one-fifth of the current diameter of the rotary roller.

[0053] If the test results show that a local diameter is larger than the preset diameter of the glass-coated filament core alloy wire, the diameter of the rotary roller is gradually replaced with two-thirds of the current rotary roller diameter until a glass-coated filament core alloy wire with the same preset diameter is obtained.

[0054] If the diameter of the replaced rotary roller is less than twice the diameter of the glass-coated filament, then the winding speed is adjusted: when the test results show that the diameter of some parts is greater than the diameter of the preset glass-coated filament core alloy wire, the winding speed is adjusted to half of the current winding speed. If the diameter of some parts is still greater than the diameter of the preset glass-coated filament core alloy wire, then the diameter of the rotary roller is gradually replaced with two-thirds of the current rotary roller diameter.

[0055] If the test results show discontinuous local diameters larger than the preset diameter of the glass-coated filament core alloy wire, the winding speed is adjusted to four-fifths of the current speed. This adjustment is repeated until a glass-coated filament core alloy wire with the same preset diameter is obtained. The peeling effect is further optimized through coarse and fine adjustments.

Claims

1. A continuous preparation apparatus for bare metal wires, characterized in that, It includes a wire feeding mechanism for providing glass-coated wire, a peeling mechanism for removing the outer glass layer of the glass-coated wire, a cleaning mechanism, a winding mechanism for winding the inner alloy wire of the glass-coated wire, and a control system used in conjunction with the winding mechanism. The wire feeding mechanism includes a feeding shaft for mounting the wire roll and an axial end cap that cooperates with the feeding shaft. The axial end cap is used to restrict the axial sliding of the wire roll. The peeling mechanism includes a frame and a rotary roller mounted on the frame. The rotary roller is used for winding the glass coating wire to form a rotary conveying direction. The diameter of the rotary roller is 2 to 6 times the diameter of the input glass coating wire. The cleaning mechanism is used to remove glass fragments adhering to the alloy wire core of the winding glass-coated filament. The control system includes a diameter detection component installed at the winding inlet of the winding mechanism, and a control circuit. The control circuit adjusts the winding speed of the winding mechanism or replaces rotary rollers of different diameters by comparing the detection result of the diameter detection component with the diameter required by the preset process.

2. The continuous preparation apparatus for bare metal wires according to claim 1, characterized in that, The peeling mechanism also includes a support cover disposed outside the frame, which is used to support the rotary roller, prevent glass fragments from splashing, and collect glass fragments in a concentrated manner.

3. The continuous preparation apparatus for bare metal wires according to claim 1, characterized in that, The winding speed of the winding mechanism ranges from 0.1 m / min to 10 m / min.

4. The continuous preparation apparatus for bare metal wires according to claim 1, characterized in that, The cleaning mechanism includes an ultrasonic cleaner with a cleaning tank, and a guide wheel disposed in the cleaning tank to guide the glass-coated filaments into the cleaning tank.

5. The continuous preparation apparatus for bare metal wires according to claim 1, characterized in that, The rotary roller is made of high-hardness, high-rigidity and wear-resistant metal rods.

6. A continuous preparation method, characterized in that, This is achieved using the continuous preparation apparatus for bare metal wires as described in claim 1, and the steps include the following: The roll of material with unprocessed glass-coated filaments is placed on the feeding shaft and axially fixed by the axial end cap; The unprocessed glass-coated filaments on the roll are extracted and passed sequentially through the peeling and cleaning mechanisms until they reach the winding mechanism. Test start the equipment to ensure that the peeling mechanism, cleaning mechanism, and diameter detection component are operating normally, and that the glass covering wire is running normally; Adjust the winding speed or replace the rotary roller with one of different diameters based on the detection results of the diameter detection component until a glass-coated filament core alloy wire with the same preset diameter is obtained.

7. The continuous preparation method according to claim 6, characterized in that, Adjusting the winding speed or replacing the rotary roller with one of different diameters based on the detection results from the diameter detection component includes the following: If the test results show that the diameter of a local area is larger than the diameter of the preset glass-coated filament core alloy wire, then the diameter of the rotary roller will be replaced with one-fifth of the current diameter of the rotary roller. If the test results show that a local diameter is larger than the preset diameter of the glass-coated filament core alloy wire, the diameter of the rotary roller is gradually replaced with two-thirds of the current rotary roller diameter until a glass-coated filament core alloy wire with the same preset diameter is obtained. If the diameter of the replaced rotary roller is less than twice the diameter of the glass-coated filament, then the winding speed is adjusted: when the test results show that the diameter of some parts is greater than the diameter of the preset glass-coated filament core alloy wire, the winding speed is adjusted to half of the current winding speed. If the diameter of some parts is still greater than the diameter of the preset glass-coated filament core alloy wire, then the diameter of the rotary roller is gradually replaced with two-thirds of the current rotary roller diameter. If the test results show that a local diameter is discontinuously larger than the preset diameter of the glass-coated filament core alloy wire, the winding speed is adjusted to four-fifths of the current speed. This adjustment is repeated until a glass-coated filament core alloy wire with the same preset diameter is obtained.

Images