Insulated wires, and methods and apparatuses for fabricating insulated wire segments

Abstract

To provide insulated wires that are cuttable to a desired length.SOLUTION: An insulated wire (100) includes a core body (110) comprising electrically-conductive material. The insulated wire also includes a permanent coating (120) comprising electrically-insulating material and disposed on the core body (110) to electrically insulate the core body (110). The insulated wire (100) further includes a removable coating (130) disposed on the permanent coating (120) to provide the core body (110) and the permanent coating (120) with structural support during cutting of the core body (110) and the permanent coating (120) to the desired length.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to wire manufacturing, and more particularly to insulated wire and methods and apparatus for manufacturing insulated wire segments. [Background technology]

[0002] Typical insulated wire consists of a conductive core coated with an electrically insulating material, such as glass or various insulating polymers, that provides electrical insulation to the wire and also provides some electrical shielding to the conductive core.

[0003] Electrically insulated wire is not commercially available in the desired minute lengths. Existing methods for cutting insulated wire to minute lengths include using high-power lasers and electrical discharge machines, but these are expensive and difficult to scale to the desired minute lengths.

[0004] Mechanical cutting methods have also been used to cut insulated wire into microwires of desired small length increments. Existing mechanical cutting methods result in defects in the microwires cut to the desired small lengths, particularly for microwires formed with a glass-coated conductive core. The glass typically breaks, cracks extensively, or is completely detached from the conductive core.

[0005] Although advances have already been made, those skilled in the art continue to conduct research and development efforts in the area of ​​wire manufacturing, including cutting insulated wire into microwires at desired minute lengths. Summary of the Invention

[0006] An insulated wire that can be cut to a desired length is disclosed.

[0007] In one embodiment, an insulated wire of the present disclosure includes a core constructed of an electrically conductive material, a permanent coating constructed of an electrically insulating material and disposed on the core to electrically insulate the core, and a removable coating disposed on the permanent coating to provide structural support to the core and permanent coating when the core and permanent coating are cut to a desired length.

[0008] A method for making the insulated wire segments is also disclosed.

[0009] In one embodiment, a manufacturing method of the present disclosure includes applying a removable coating material to a length of insulated wire to obtain a length of coated insulated wire. The method also includes cutting the length of coated insulated wire to a desired length to obtain a coated insulated wire segment. The method optionally further includes removing the removable coating material from the coated insulated wire segment.

[0010] In another embodiment, the manufacturing method of the present disclosure includes cutting a length of insulated wire into insulated wire segments of the desired length using at least one pair of a plurality of cutting blades spaced apart from one another by substantially the desired length.

[0011] An apparatus for producing insulated wire segments is also disclosed.

[0012] In one embodiment, the manufacturing apparatus of the present disclosure includes a blade assembly comprised of between about 10 and about 1000 cutting blades. The cutting blades are spaced apart by approximately a desired length. The blade assembly can be manually or automatically operated such that the cutting blades can sever the insulated wire into insulated wire segments.

[0013] Other embodiments of the insulated wire, manufacturing method, and manufacturing apparatus of the present disclosure will become apparent from the following detailed description, the accompanying drawings, and the claims. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a perspective view of an insulated wire made according to one embodiment. [Figure 2A] 2 is an elevational view of a manufacturing apparatus for cutting the insulated wire of FIG. 1 made in accordance with one embodiment. [Figure 2B] 2B is an elevational view taken generally in the direction of arrow 2B of FIG. 2A. [Figure 3] FIG. 1 is a perspective view of an insulated wire segment manufactured according to one embodiment. [Figure 3A] 3A is an elevational view taken generally in the direction of arrow 3A of FIG. 3, illustrating the dimensions and layers of the insulated wire segment. [Figure 3B] 3B is an elevational view showing the dimensions of the insulated wire segment taken generally in the direction of arrow 3B of FIG. 3. [Figure 4] 4 is a flowchart illustrating a method of producing the insulated wire segment of FIG. 3 from the insulated wire of FIG. 1 according to one embodiment. [Figure 5] 4 is a flow chart illustrating a method of producing the insulated wire segment of FIG. 3 from the insulated wire of FIG. 1 according to another embodiment. [Figure 6] FIG. 1 is a block diagram of an aircraft production and service method. [Figure 7] FIG. 1 is a schematic diagram of an aircraft. DETAILED DESCRIPTION OF THE INVENTION

[0015] This application relates to insulated wire and methods and apparatus for manufacturing insulated wire segments. The specific configurations of the insulated wire, manufacturing methods, and manufacturing apparatus, as well as the industries in which the insulated wire, manufacturing methods, and manufacturing apparatus are implemented, vary widely. The following disclosure provides multiple embodiments or examples for implementing different features of various embodiments. To simplify the disclosure, specific examples of components and arrangements are described. These are merely examples and are not intended to be limiting.

[0016] Referring to FIG. 1 , a perspective view of an insulated wire 100 made according to one embodiment is shown. The insulated wire 100 includes a core 110 constructed of a conductive material. The conductive material of the core 110 includes a metallic material. The metallic material may include at least one of nickel, iron, carbon, copper, cobalt, chromium, permalloy, and stainless steel. Other types of conductive materials are also possible. The diameter "C" of the core 110 is between about 1 micrometer and about 50 micrometers. Other diameter dimensions of the core 110 are also possible.

[0017] The insulated wire 100 also includes a permanent coating 120 constructed from an electrically insulating material and disposed on the core 110 to electrically insulate the core 110. The permanent coating 120 may be constructed from, for example, glass. Other electrically insulating materials, such as electrically insulating polymers, are also possible. The combined total diameter "D" of the core 110 and permanent coating 120 is between approximately 5 micrometers and 500 micrometers.

[0018] The insulated wire 100 further includes a removable coating 130 disposed on the permanent coating 120. The removable coating 130 can be composed of a polymeric material, such as at least one of a thermoplastic material and a thermosetting material. The electrically insulating polymeric material of the removable coating 130 can be, for example, a coating having a dielectric constant greater than 1 as measured in accordance with ASTM D149. As one specific, non-limiting example, the removable coating 130 can be composed of CrystalBond 509, available from SPI Supplies, Inc., located in West Chester, Pennsylvania. Other types of electrically insulating polymeric materials are also possible.

[0019] When the removable coating 130 is composed of a thermoplastic material, the thermoplastic material can be removed by at least one of dissolving in a solvent, melting, and burning (i.e., pyrolysis). The thermoplastic material can be removed by dissolving in a solvent, such as a solvent composed of at least one of a ketone, an alcohol, water, and a halogen. Other methods of removing the thermoplastic material are also possible. The removable coating 130 can be applied to a single wire, a bundle of wires, or an array of wires. It is also contemplated that a pattern of wires can be disposed within the removable coating 130.

[0020] If the removable coating 130 is composed of a thermosetting material, the thermosetting material can be removed by burning it off. Other methods of removing the thermosetting material are also contemplated.

[0021] Other types of materials are possible for the removable coating 130. By way of example, the removable coating 130 can be composed of at least one of acrylic, polyurethane, epoxy, polysiloxane, polyurea, polyether, and polyester.

[0022] According to one aspect of the present disclosure, the insulated wire 100 can be cut to a desired length. The desired length of the insulated wire segment (i.e., a segment of the insulated wire 100 cut to a desired length) is on the microscale, such as between about 10 micrometers and 500 micrometers. Note that the removable coating 130 provides structural support to the core 110 and the permanent coating 120 when the core 110 and the permanent coating 120 are cut to a desired length, as described later in this specification.

[0023] Referring to Figure 2A, there is shown an elevational view of a manufacturing apparatus 200 for cutting the insulated wire 100 of Figure 1. The manufacturing apparatus 200 is made in accordance with one embodiment. Figure 2B is an elevational view looking generally in the direction of arrow "2B" in Figure 2A.

[0024] As shown in FIG. 2A , the manufacturing apparatus 200 is ready to cut the insulated wires 100 (five insulated wires in FIG. 2A ). Each of the five insulated wires 100 is supported on a cutting plate / cutting surface (e.g., anvil) 208. For illustrative purposes, each of the five insulated wires 100 is shown enlarged in FIG. 2A . While five insulated wires are shown ready to be cut, one skilled in the art will recognize that fewer or more than five insulated wires (e.g., 100 or more, 1000 or more, etc.) may be cut at one time depending on the size and configuration of the manufacturing apparatus 200.

[0025] The manufacturing apparatus 200 includes a blade assembly 210 that can be pushed vertically downward in the direction of arrow "A" shown in FIG. 2A to cut the insulated wire 100. The blade assembly 210 includes a blade retaining member 211 to which an array of blades 212 is secured. In one specific, non-limiting example, the array of blades 212 are interconnected using, for example, a common pin 214 inserted through an aperture in each blade 212 of the array of blades 212, as best shown in FIG. 2B, and secured with a mechanical fastener (e.g., nut) 216. The array of interconnected blades 212 can then be secured to the blade retaining member 211 by heating the blades to partially melt adjacent portions of the blade retaining member 211, thereby melt-bonding the array of interconnected blades 212 to the blade retaining member 211. In another non-limiting example, an adhesive may be used to secure the blades 212 (e.g., the array of interconnected blades 212) to the blade retaining member 211. As shown in FIG. 2B, the spacing "B" between adjacent blades is exaggerated for illustrative purposes.

[0026] The blade-retaining member 211 can be fabricated, for example, by 3D printing, and functions as a blade holder for the blades 212 to properly space the blades 212. The blunt edges of the blades 212 are recessed into the blade-retaining member 211 and secured to the blade-retaining member 211 by fusion bonding, adhesive bonding, mechanical means, etc. The sharp edges of the blades 212 face outward from the blade-retaining member 211 and are adapted to cut wire.

[0027] The array of blades 212 in the blade assembly 210 can be any number of cutting blades, for example, between about 10 and about 1000 cutting blades spaced apart by a desired length. The blades 212 are precisely spaced apart by a distance between about 100 micrometers and about 500 micrometers. Typically, the blades 212 are spaced apart by about 250 micrometers. The length of the blades 212 is perpendicular to the length of the wire being cut.

[0028] The blades 212 can cut at any speed, such as between about 100 cuts per second and about 10,000,000 cuts per second. The cutting speed depends on the number of insulated wires to be cut that are placed under the blade holder 211, the number of blades 212 in the blade assembly 210, and whether the blade assembly 210 (i.e., a mechanical device) is manually or automatically forced, compressed, squeezed, or retracted against the cutting plate / cutting surface 208 to cut the insulated wire (e.g., the insulated wire 100 shown in FIG. 1 ) into insulated wire segments (as described later herein). The blade assembly 210 can be operated manually or automatically by connecting it to a motor or robot (not shown). In operation, the blades 212 simultaneously cut the insulated wire in a guillotine-like fashion.

[0029] Although the above description describes cutting the insulated wire 100 by forcing the blade assembly 210 vertically downward against the cutting plate / cutting surface 208 in the direction of arrow "A" shown in FIG. 2A, it is contemplated that the blade assembly 210 may be forced in any direction depending on the spatial relationship between the blade assembly 210 and the cutting plate / cutting surface 208.

[0030] Referring to Figure 3, there is shown a perspective view of an insulated wire segment 300 manufactured in accordance with one embodiment. Figure 3A is an elevation view looking generally in the direction of arrow "3A" in Figure 3. Figure 3A illustrates the dimensions and layers of insulated wire segment 300. Figure 3B is an elevation view looking generally in the direction of arrow 3B in Figure 3. Figure 3B illustrates the dimensions of insulated wire segment 300.

[0031] The insulated wire segment 300 shown in Figures 3, 3A, and 3B is obtained by cutting an insulated wire (e.g., the insulated wire 100 shown in Figure 1) to a desired length using a manufacturing apparatus (e.g., the manufacturing apparatus 200 shown in Figures 2A and 2B). As shown in Figures 3, 3A, and 3B, the insulated wire segment 300 includes three layers: a core 110, a permanent coating 120, and a removable coating 130. The combined total diameter "E" of the core 110, the permanent coating 120, and the removable coating 130 is between about 20 micrometers and about 150 micrometers. Other dimensions are possible. The length "L" of the insulated wire segment 300 is between about 100 micrometers and about 500 micrometers. Other lengths are possible.

[0032] Providing the insulated wire 100 of Figure 1 provides many advantages. One advantage is that the removable coating 130 of the insulated wire 100 acts as a protective casing, providing structural support when the core 110 and permanent coating 120 are cut to the desired length. This is particularly beneficial when the permanent coating 120 is composed of glass, which tends to break, crack, or peel from the core 110 when cut. As a result, the yield of insulated wire segments is increased, reducing the manufacturing costs associated with producing insulated wire segments from the insulated wire 100.

[0033] Another advantage is that the removable coating 130 can be left as part of the insulated wire segment 300 or can be removed if desired. If the removable coating 130 is left as part of the insulated wire segment 300, the removable coating 130 provides additional electrical insulation. Also, placing a wire pattern on the removable coating 130 provides additional electrical insulation.

[0034] As yet another advantage, the manufacturing apparatus 200 of FIG. 2 can be used to achieve high throughput rates in cutting the insulated wire segments to the desired length, particularly when the blade assembly 210 of the manufacturing apparatus 200 is automatically controlled using either a motor or a robot.

[0035] Yet another advantage of providing the insulated wire 100 of Figure 1 is that the expensive machinery currently used to cut the insulated wire into desired microscale length insulated wire segments is eliminated. The manufacturing apparatus 200 of Figure 2 is used in place of the expensive machinery currently used. Furthermore, the long setup times associated with the expensive machinery currently used are eliminated. As a result, costs are reduced because the expensive machinery and the labor required to operate these expensive machines are eliminated.

[0036] Referring to Figure 4, a flowchart 400 illustrates a method for producing the insulated wire segment 300 of Figure 3 from the insulated wire 100 of Figure 1, according to one embodiment. At block 410, a removable coating material is applied to a length of insulated wire to obtain a coated length of insulated wire. The process proceeds to block 420, where the coated length of insulated wire is cut to a desired length to obtain a coated insulated wire segment. Next, at block 430, optionally, the removable coating material is removed from the coated insulated wire segment. The process then ends.

[0037] In some embodiments, a mechanical device is pushed by a selected one of a motor, a robot, and a hand to cut a given length of coated insulated wire to a desired length.

[0038] In some embodiments, between about 10 and about 1000 cutting blades are used to cut a given length of coated insulated wire to the desired length.

[0039] In some embodiments, cutting occurs at between about 100 cuts per second and about 10,000,000 cuts per second.

[0040] Referring to Figure 5, a flowchart 500 illustrates a method for producing the insulated wire segment 300 of Figure 3 from the insulated wire 100 of Figure 1 according to another embodiment. At block 510, a given length of insulated wire is cut into insulated wire segments of the desired length using at least one pair of cutting blades spaced apart by approximately the desired length. The process then ends.

[0041] In some embodiments, a length of glass-insulated wire is cut to a desired length, which is between about 10 micrometers and about 500 micrometers in length.

[0042] In some embodiments, a mechanical device is applied by a selected one of a motor, a robot, and a hand to cut the insulated wire to the desired length.

[0043] In some embodiments, between about 10 and about 1000 cutting blades are used to cut the insulated wire into a plurality of insulated wire segments by a selected one of a motor, a robot, and by hand.

[0044] In some embodiments, cutting occurs at between about 100 cuts per second and about 10,000,000 cuts per second.

[0045] As is apparent from the above description, removable coating 130 (FIGS. 1 and 3) may be part of an applique or spray-on coating in an aerospace environment. Insulated wire segments, such as insulated wire segment 300 shown in FIG. 3, may be used in the manufacture of appliques or spray-on coatings. Insulated wire segment 300 may be used in many different applications in an aerospace environment.

[0046] Embodiments of the disclosure may be described with reference to aircraft manufacturing and service method 1100 shown in Figure 6 and with reference to aircraft 1102 shown in Figure 7. Prior to the start of production, aircraft manufacturing and service method 1100 includes specification and design 1104 of the aircraft 1102 and material procurement 1106. During production, component / subassembly manufacturing 1108 and system integration 1110 of the aircraft 1102 occurs. The aircraft 1102 then undergoes certification and delivery 1112 and enters into service 1114. While in customer service, the aircraft 1102 undergoes a schedule of routine maintenance and service 1116, which may include modifications, reconfigurations, refurbishments, etc.

[0047] The steps of method 1100 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). A system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors. A third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers. An operator may include, but is not limited to, an airline, a leasing company, a military entity, a service organization, etc.

[0048] 7, aircraft 1102 produced by example method 1100 may include an airframe 1118 having a number of systems 1120 and an interior 1122. Examples of systems 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may also be included.

[0049] The disclosed insulated wire, manufacturing apparatus, and manufacturing methods may be employed during any one or more steps of aircraft manufacturing and service method 1100. As one example, components or subassemblies corresponding to component / subassembly manufacturing 1108, system integration 1110, and / or maintenance and service 1116 may be assembled using the disclosed insulated wire, apparatus, and methods. As another example, airframe 1118 may be fabricated using the disclosed insulated wire, materials and / or coatings including the insulated wire, apparatus, and methods. Additionally, use of one or more insulated wire embodiments, apparatus embodiments, method embodiments, or a combination thereof during component / subassembly manufacturing 1108 and / or system integration 1110 may substantially increase the speed and / or reduce the cost of assembly of aircraft 1102, such as airframe 1118 and / or interior 1122. Similarly, one or more insulated wire embodiments, apparatus embodiments, method embodiments, or combinations thereof may be used while the aircraft 1102 is in service, for example, but not limited to, during maintenance and service 1116 .

[0050] Various embodiments of the insulated wire, devices, and methods disclosed herein include various components, features, and functions, and it is understood that various embodiments of the insulated wire, devices, and methods disclosed herein may include any of the components, features, and functions of other embodiments of the insulated wire, devices, and methods disclosed herein, in any combination, and all such possibilities are intended to be within the scope of the present disclosure.

[0051] The insulated wire, apparatus, and methods described above are described in the context of aircraft. However, one skilled in the art will readily recognize that the insulated wire, apparatus, and methods of the present disclosure are suitable for a variety of applications, and the present disclosure is not limited to aerospace applications. For example, the insulated wire, apparatus, and methods of the present disclosure can be implemented in various types of vehicles, including, for example, helicopters, passenger ships, automobiles, and marine products (boats, motors, etc.). Applications other than vehicles are also contemplated.

[0052] While the above description describes insulated wire, an apparatus for producing insulated wire segments, and a method for producing insulated wire segments in an aerospace environment, it is contemplated that the insulated wire, the apparatus, and the method may be practiced in any industry in accordance with applicable industry standards. The particular insulated wire, the apparatus, and the method may be selected and tailored to a particular application.

[0053] Also, while various example embodiments of the present disclosure have been shown and described, modifications may occur to those skilled in the art upon reading this specification, and the present application is intended to include such modifications and is limited only by the scope of the claims.

Claims

1. An insulated wire that can be cut to a desired length, a core body including a conductive material; a permanent coating disposed on the core to electrically insulate the core, the permanent coating comprising an electrically insulating material; a removable coating disposed on the permanent coating to provide structural support to the core and the permanent coating when the core and the permanent coating are cut to the desired length.

2. The insulated wire of claim 1 , wherein the conductive material of the core comprises a metallic material.

3. 3. The insulated wire of claim 2, wherein the metallic material comprises at least one of nickel, iron, carbon, copper, cobalt, chromium, permalloy, and stainless steel.

4. 10. The insulated wire of claim 1, wherein the core diameter is between 1 micrometer and 50 micrometers.

5. The insulated wire of claim 1 , wherein the permanent coating comprises glass.

6. 10. The insulated wire of claim 1, wherein the total diameter of the core and the permanent coating is between 5 micrometers and 500 micrometers.

7. The insulated wire of claim 1 , wherein the removable coating comprises at least one of a thermoplastic material and a thermoset material.

8. 10. The insulated wire of claim 1, wherein the removable coating comprises a thermoplastic material that is removable by at least one of dissolving in a solvent, melting, and burning.

9. 9. The insulated wire of claim 8, wherein the thermoplastic material is removable by dissolution in a solvent, the solvent including at least one of a ketone, an alcohol, water, and a halogen.

10. 10. The insulated wire of claim 1, wherein the removable coating comprises a thermosetting material, the thermosetting material being removable by combustion.

11. 10. The insulated wire of claim 1, wherein the removable coating comprises at least one of an acrylic, a polyurethane, an epoxy, a polysiloxane, a polyurea, a polyether, and a polyester.

12. 10. The insulated wire of claim 1, wherein the desired length is between 10 micrometers and 500 micrometers.

13. 1. A method for producing an insulated wire segment, comprising: applying a removable coating material to a length of insulated wire to obtain a coated length of insulated wire; cutting the length of coated insulated wire to a desired length to obtain a coated insulated wire segment; and optionally removing said removable coating material from said coated insulated wire segment.

14. Cutting the length of coated insulated wire includes:

14. The method of claim 13, comprising applying a mechanical device by a selected one of a motor, a robot, and a hand to cut the given length of coated insulated wire to the desired length.

15. Cutting the length of coated insulated wire includes:

14. The method of claim 13, comprising making the cuts with between 10 and 1000 cutting blades to achieve the desired cut in the length of coated insulated wire.

16. Cutting the length of coated insulated wire includes:

14. The method of claim 13, comprising making cuts at between 100 cuts per second and 10,000,000 cuts per second.

17. 1. A method for producing an insulated wire segment, comprising:

1. A method comprising: cutting a length of insulated wire into insulated wire segments of the desired length using at least one pair of a plurality of cutting blades spaced apart from one another by substantially the desired length.

18. Cutting the given length of insulated wire to a desired length comprises:

20. The method of claim 17, comprising cutting a length of glass-insulated wire to a desired length, the desired length being between 10 micrometers and 500 micrometers in length.

19. Cutting the given length of insulated wire to a desired length comprises:

20. The method of claim 17, comprising applying a mechanical device by a selected one of a motor, a robot, and a hand to cut the insulated wire to a desired length.

20. Cutting the given length of insulated wire to a desired length comprises:

20. The method of claim 17, comprising cutting the insulated wire into a plurality of insulated wire segments using between 10 and 1000 cutting blades by a selected one of a motor, a robot, and by hand.

21. Cutting the given length of insulated wire to a desired length comprises:

20. The method of claim 17, comprising making cuts at between 100 cuts per second and 10,000,000 cuts per second.

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