Prebending device and methods

Abstract

A prebending device is provided for selective attachment to a braider carrier and operative on a portion of a wire strand imposed operationally between a feed spool and the braider carrier. The prebending device includes an elongate guide rail attachable to the braider carrier. A carrier block is supported by the at least one guide rail for sliding movement therealong selectively. A plurality of idler wheels is concurrently carried by the carrier block. The plurality of idler wheels collectively defines a serpentine wire strand travel path operationally between a wire entry point, from the feed spool, a wire exit point, toward the braider carrier. A predetermined wire bend radius is imposed upon the wire strand responsive to at least one of a spring-bias force imparted on the carrier block and an effective diameter of an idler wheel. A method of using the prebending device is also provided.

Description

Docket No. A0012005W001PREBENDING DEVICE AND METHODSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 681,302, filed August 9, 2024, the entire content of which is incorporated herein by reference.FIELD

[0002] The present technology is related generally to a prebending device for selective attachment to a braider carrier and related methods.BACKGROUND

[0003] Braiding machines can be used in industrial settings to braid wire strands (having any suitable cross-sectional shape) into a cable, tube, sheath, or any other desired elongate shape. The wire strands are commonly supplied on large supply spools which are mounted on braider carriers of the braiding machines. The braider carriers are rotated, precessed, shifted, or moved in any other suitable manner to produce a final braided product having a desired configuration. The wire strands are often biased (whether intentionally or not) into a curved shape responsive to a diameter of the feed spool from which they are taken. However, in some use environments, it may be undesirable for the braided wire strand(s) to maintain that initial curved bias. For example, if the curved bias from the feed spool has a larger radius of curvature than the final braided product, portions of the wire strand may tend to splay outward undesirably after the braiding process has been completed.SUMMARY

[0004] The techniques of this disclosure generally relate to a prebending device for selective attachment to a braider carrier and operative on a portion of a wire strand imposed operationally between a feed spool and the braider carrier, as well as methods for providing and using a prebending device.Docket No. A0012005W001

[0005] In one aspect, alone or in combination with any other aspect, the present disclosure provides a prebending device for selective attachment to a braider carrier and operative on a portion of a wire strand imposed operationally between a feed spool and the braider carrier. The prebending device includes at least one elongate guide rail having longitudinally spaced first and second rail ends and configured for selective attachment to the braider carrier. A carrier block is supported by the at least one guide rail for sliding movement therealong selectively at least partially between the first and second rail ends. The carrier block is spring-biased toward the first rail end. A plurality of idler wheels is concurrently carried by the carrier block. At least one idler wheel is rotatable about a wheel axis substantially perpendicular to the guide rail. The plurality of idler wheels collectively defines a serpentine wire strand travel path operationally between a wire entry point, from the feed spool, adjacent the first rail end and a wire exit point, toward the braider carrier, adjacent the second rail end. The serpentine wire strand travel path includes at least two directional changes, of at least ninety degrees each, collectively imparted by the plurality of idler wheels. A predetermined wire bend radius is imposed upon the wire strand responsive to at least one of a spring-bias force imparted on the carrier block and an effective diameter of at least a chosen idler wheel.

[0006] In one aspect, alone or in combination with any other aspect, the present disclosure provides a method of prebending a wire strand for incorporation into at least one of a wire rope and a wire braid. The method includes extending the wire strand along a wire strand travel path between a feed spool and a braider carrier. A plurality of idler wheels is provided. At least one idler wheel is rotatable about a wheel axis substantially perpendicular to the wire strand travel path. The plurality of idler wheels is concurrently carried on a carrier block. The carrier block, carrying the plurality of idler wheels, is selectively slid longitudinally along at least one elongate guide rail. The guide rail is selectively attached to the braider carrier. The carrier block is spring-biased toward a first rail end of the guide rail. With the plurality of idler wheels, a serpentine portion of the wire strand travel path is collectively defined, the serpentine portion of the wire strand travel path being interposed operationally between a wire entry point, from the feed spool, adjacent the first rail end and a wire exit point, toward the braider carrier, adjacent the second rail end. By the plurality of idler wheels, at least two directional changes of at least ninety degrees each are imparted. A predetermined wire bendDocket No. A0012005W001 radius is imposed upon the wire strand responsive to at least one of a spring-bias force imparted on the carrier block and an effective diameter of at least a chosen idler wheel.

[0007] The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the techniques described in this disclosure will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF DRAWINGS

[0008] Fig. 1 is a side view of a first embodiment of a prebending device according to an aspect of the present disclosure, in a first condition and an example use environment;

[0009] Fig. 2 is a perspective front view of the prebending device of Fig. 1;

[0010] Fig. 3 is a partial perspective top view of the prebending device of Fig. 1 ;

[0011] Fig. 4 is a side view of a component of the prebending device of Fig. 1 ;

[0012] Fig. 5 is a perspective top view of the component of Fig. 4;

[0013] Fig. 6 is a perspective front view of the component of Fig. 4;

[0014] Fig. 7 is a schematic top view of the prebending device of Fig. 1 ;

[0015] Fig. 8 is a schematic side view of the prebending device of Fig. 1 ;

[0016] Fig. 9 is an exploded schematic top perspective view of the prebending device ofFig. 1;

[0017] Fig. 10 is a perspective top view of the prebending device of Fig. 1, in a second condition;

[0018] Fig. 11 is a perspective bottom view of the prebending device of Fig. 10;

[0019] Fig. 12 is a perspective rear view of the prebending device of Fig. 10;

[0020] Fig. 13 is a top view of the prebending device of Fig. 10;

[0021] Fig. 14 is a schematic view of a wire path of any embodiment of the present disclosure;

[0022] Fig. 15 is a perspective front view of a second embodiment of a prebending device according to an aspect of the present disclosure;

[0023] Fig. 16 is a perspective bottom view of the prebending device of Fig. 15;

[0024] Fig. 17 is a perspective rear view of the prebending device of Fig. 15;Docket No. A0012005W001

[0025] Fig. 18 is an exploded schematic top perspective view of the prebending device of Fig. 15; and

[0026] Fig. 19 is a perspective rear view of the prebending device of Fig. 15 in an example use environment.DETAILED DESCRIPTION

[0027] As used herein, the singular forms “a”, “an”, and “the” can include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising”, as used herein, can specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0028] As used herein, the term “and / or” can include any and all combinations of one or more of the associated listed items.

[0029] As used herein, phrases such as “between X and Y” and “between about X and Y” can be interpreted to include X and Y

[0030] It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, “adjacent”, etc., another element, it can be directly on, attached to, connected to, coupled with, contacting, or adjacent the other element, or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with, “directly contacting”, or “directly adjacent” another element, there are no intervening elements present. It will also be appreciated by those of ordinary skill in the art that references to a structure or feature that is disposed “directly adjacent” another feature may have portions that overlap or underlie the adjacent feature, whereas a structure or feature that is disposed “adjacent” another feature might not have portions that overlap or underlie the adjacent feature.

[0031] Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “proximal”, “distal”, and the like, may be used herein for ease of description to describe oneDocket No. A0012005W001 element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms can encompass different orientations of a device in use or operation, in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features.

[0032] As used herein, the phrase “at least one of X and Y” can be interpreted to includeX, Y, or a combination of X and Y. For example, if an element is described as having at least one of X and Y, the element may, at a particular time, include X, Y, or a combination of X andY, the selection of which could vary from time to time. In contrast, the phrase “at least one of X” can be interpreted to include one or more Xs.

[0033] It will be understood that, although the terms “first”, “second”, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. Thus, a “first” element discussed below could also be termed a “second” element without departing from the teachings of the present disclosure. The sequence of operations (or steps) is not limited to the order presented in the claims or figures unless specifically indicated otherwise.

[0034] The attached drawings are not shown at scale, and distances therein are not necessarily absolute or relative depictions of locations and interactions of the depicted structures. One of ordinary skill in the art will be able to interpret the drawings and specification of the present application for a particular use environment of the technology(ies) described and shown.

[0035] The “longitudinal” direction, as referenced herein, is substantially parallel to longitudinal arrow “Lo” in the Figures and is substantially horizontal, in the orientation of Fig. 1.

[0036] The “lateral” direction, as referenced herein, is substantially parallel to the “La” arrow in the Figures and is substantially perpendicular to the longitudinal direction.

[0037] The “transverse” direction, as referenced herein, is substantially parallel to the “T” arrow in the Figures and is substantially perpendicular to both the longitudinal and lateral directions.Docket No. A0012005W001

[0038] The invention comprises, consists of, or consists essentially of the following features, in any combination.

[0039] Figs. 1-13 depict a prebending, preshaping, or curling device (referenced hereafter as a prebending device 100) according to a first aspect of the present invention. The prebending device 100 is provided for selective attachment to a braider carrier 102 and operative on a portion of a wire strand 104 imposed operationally between a feed spool 106 and the braider carrier 102. The braider carrier 102 may be any suitable commercially available and / or custom-made braider carrier 102. For example, a suitable braider carrier 102, shown in the Figures, forms a portion of a braiding machine available from Steeger USA of Inman, South Carolina. However, it is contemplated that a prebending device 100 could be configured for any desired use environment by one of ordinary skill in the art, following the teachings in this application.

[0040] The prebending device 100 includes at least one elongate guide rail 106 having longitudinally spaced first and second rail ends, 108 and 110, respectively. The at least one guide rail 106 (first and second guide rails 106 are shown in Figs. 1-13, by way of example) is configured for selective attachment to the braider carrier 102, directly or indirectly. A carrier block 112 is supported by the at least one guide rail 106 for sliding movement therealong selectively at least partially between the first and second rail ends 108 and 110.

[0041] The carrier block 112 includes a plurality of longitudinal through-holes 111. Each of the first and second guide rails 106 extends through a selected through-hole 111 to support the carrier block 112 for longitudinal sliding motion with respect to the first and second guide rails 106. (For some example use environments, the provision of a plurality of guide rails 106 may assist with preventing “twisting” of the carrier block 112 around the longitudinal axis during movement.) This sliding movement of the carrier block 100 along the guide rail(s) 106 will be reciprocal movement, in many use environments of the prebending device 100. The carrier block 112 is spring-biased toward the first rail end 108. The first and second rail ends 108 and 110 may be spaced longitudinally apart from one another. Figs. 1-3 generally depict the prebending device 100 connected to the braider carrier 102, with a feed spool 114 carrying the wire strand 104 and feeding out the wire strand 104 toward a remaining portion of the braider machine (not shown).Docket No. A0012005W001

[0042] As can be seen in Figs. 1-3, a plurality of idler wheels 116 is concurrently carried by the carrier block 112. At least one idler wheel 116 is rotatable about a wheel axis 118 which is substantially perpendicular to the guide rail 106. For example, when the guide rail 106 extends in the longitudinal direction, the wheel axis 118 may extend laterally. The plurality of idler wheels 116 collectively defines a serpentine wire strand travel path P operationally between a wire entry point (shown schematically at 120 as traveling into the prebending device 100), from the feed spool 114 and a wire exit point (shown schematically at 122 as traveling out from the prebending device 100), toward the braider carrier 102. The serpentine wire strand travel path P will be further discussed below with reference at least to Figs. 4-6. The wire entry point 120 is adjacent the first rail end 108, and the wire exit point 122 is adjacent the second rail end 110.

[0043] A predetermined wire bend radius is imposed upon the wire strand 104 during operation of the prebending device 100 responsive to at least one of a spring-bias force imparted on the carrier block 112 and an effective diameter of at least a chosen idler wheel 116. For many use applications, such as braiding a tube, sheath, cable, or other elongate multi-strand braided product with the braiding machine, that predetermined wire bend radius produced through use of the prebending device 100 may be a different magnitude than is an initial wire bend radius of the wire strand 104, such as the initial wire bend radius produced by the wire manufacturer’s wrapping of the wire strand 104 around the feed spool 114, and / or a “set” picked up by the wire strand 104 from the feed spool 114 during storage or otherwise. (For example, the predetermined wire bend radius could be smaller than the initial wire bend radius, in order to avoid splaying of cut ends of the wire strand 104 during creation of the braided product.)

[0044] Stated broadly, the wire strand 104 is released from the feed spool 114 and fed through the prebending device 100 along the serpentine wire strand travel path P, under a predetermined amount of tension. This tension can be, for example, used to prevent tangling of the wire strand 104 during the braiding process. (E.g., the sliding motion of the carrier block 112 along the at least one guide rail 106 could be adjusted by “tuning” of the springbias force and / or the interface between the carrier block 112 and the guide rail(s) 106.) Responsive to that spring-biased tension and / or to tension imparted naturally by otherDocket No. A0012005W001 portions of the braider carrier 102 or braiding machine during passage of the wire strand 104 in contact with the at least one idler wheel 116, the wire strand 104 is formed to the predetermined wire bend radius via interaction with at least one idler wheel 116. One of ordinary skill in the art will be readily able to provide a prebending device 104 imposing a desired predetermined wire bend radius upon the wire strand 104 in order to replace or overcome the initial wire bend radius of the wire strand 104 for a particular use environment, following the teachings of the present application.

[0045] With reference now to the example configuration of a carrier block 112 shown in at least Figs. 4-6, the plurality of idler wheels 116 may include at least one transition roller 116T and at least one curler roller 116C. In this case, then, the predetermined wire bend radius is imposed upon the wire strand 104 responsive to an effective diameter of the curler roller 116C. The curler roller 116C, transition roller 116T, and / or any other idler wheels 116 which might be provided may have any desirable placement, configuration, relative spatial relationship, shape, material, or any other properties to assist in imparting the predetermined wire bend radius to the wire strand 104 as desired. For example, it is contemplated that at least one of the idler wheels 116 could rotate at a different rate than at least one other of the idler wheels 116, any of which could be prevented from rotating, for example, in a particular use environment. It is also contemplated that the wire strand 104 could be passed along a suitably configured edge (instead of the depicted rollers) to impart a desired bend or curl, in much the same manner as curling ribbon is manipulated with a scissor blade in creating a looping gift-wrapping decoration. One of ordinary skill in the art will be able to provide a prebending device 100 for a particular use environment upon review of the present description and Figures.

[0046] As exhibited by the carrier block 112 and related components assembly shown in at least Figs. 4-6, at least a portion of the transition roller 116T is positioned on the carrier block 112 longitudinally further toward the second rail end 110 than is at least a portion of the curler roller 116C. In fact, an entirety of the transition roller 116T may be positioned on the carrier block 112 longitudinally further toward the second rail end 110 than is an entirety of the curler roller 116C. One of ordinary skill in the art can readily configure the idler wheels 116 in order to create a serpentine wire strand travel path P for achieving desired results for theDocket No. A0012005W001 wire strand 104. With particular reference to Fig. 14, the serpentine wire strand travel path P may include a full rotational loop, when viewed in side profile. This full rotational loop is shown schematically at area R in Fig. 14.

[0047] Stated differently, when the wire strand travel path P is viewed from the lateral direction, a portion of the wire strand 104 exiting the transition roller 116T appears to “cross” a portion of the wire strand 104 exiting the curler roller 116C. (It should be noted that the idler wheels 116 of the prebending device 100 may be effectively offset from one another laterally, by configuration and / or positioning, to avoid content and potential tangling between portions of the wire strand 104 at different points along the serpentine wire strand travel path P.

[0048] In order to achieve desired predetermined wire bend radius imposition upon the wire strand 104 for a particular use environment, the serpentine wire strand travel path P may include at least two directional changes, of at least ninety degrees each, collectively imparted by the plurality of idler wheels 116. This arrangement is shown schematically— for any embodiment of the present technology— by angles a and 0 (associated with the transition roller 116T and the curler roller 116C, respectively), in Fig. 14. For example, the serpentine wire strand travel path P may include at least two directional changes, of between about 120 and 240 degrees each, collectively imparted by the plurality of idler wheels 116. As another example, the serpentine wire strand travel path P may include at least two directional changes, of between about 150 and 213 degrees each, collectively imparted by the plurality of idler wheels 116.

[0049] Again, one of ordinary skill in the art can readily provide any desired number and arrangement of idler wheels 116, creating any desired serpentine wire strand travel path P, and traveling around any desired angles a and 0 (which can be the same as, or different than, each other), as desired to achieve predetermined wire bend radius for a wire strand 104. It is contemplated that the carrier block 112, idler wheel(s) 116, or any other components of the prebending device 100 could be modular and readily reconfigured, such that one of ordinary skill in the art can substitute components to achieve a variety of different predetermined wire bend radii at different times, using the same prebending device 100 and potentially differing components. For example, instead of the depicted serpentine wire strand travel path PDocket No. A0012005W001 including an apparent full rotational loop (“R”) when viewed from certain angles, a “Z”, “S”, “W”, “U”, “V”, and / or “N” shaped serpentine wire strand travel path (as seen when viewed along a lateral direction, as in the depiction of Fig. 14) could be provided for a particular use environment.

[0050] Turning now to Figs. 7-13, the prebending device 100 and components thereof are shown without the feed spool 114 and wire strand 104, for the sake of description. As it is particularly apparent in Figs. 8-9, the at least one idler wheel 116 may be rotationally attached to the carrier block by an axle pin 124 extending collinearly with the wheel axis 118. In such case, the axle pin 124 extends at least partially through an arbor (center laterally oriented through hole) of the idler wheel 116. Use of an axle pin 124 is how the curler roller 116C is maintained on the carrier block 112 shown in the Figs. Idler wheel 116 could also or instead be maintained upon the carrier block 112 through use of a shoulder screw 126, as shown in Fig. 9, or any other desired fastener, whether or not the idler wheel 116 is permitted to rotate about the wheel axis 118. One of ordinary skill in the art will be able to configure the carrier block 112 to support and maintain the idler wheel(s) 116 in any desired manner for a particular use environment.

[0051] With particular reference to Figs. 7, 9, and 12-13, at least one idler wheel 116 may have a spool shape, with two oppositely spaced outer flanges 128 each having a larger diameter than a diameter of a barrel section 130 interposed between (in the orientation of the Figures, interposed laterally between) the outer flanges 128. (For clarity, the outer Flanders 128 and barrel section 130 are not labeled on each idler wheel 116 and / or each Figure, but will be apparent to one of ordinary skill in the art.) The outer flanges 128, when present, may taper inward to direct the wire strand toward the barrel section 130 of the idler wheel 116, and optionally toward a lateral center portion of the barrel section 130. Again, one of ordinary skill in the art can provide suitably configured idler wheels 116 to achieve desired direction of the wire strand 104.

[0052] As mentioned previously, the carrier block 112 is configured to reciprocate longitudinally along at least a portion of the at least one guide rail 106. A motor (not shown) or other external motive force may be controlled and powered to drive such reciprocal motion in a predetermined manner independent of forces exerted upon a prebending device in someDocket No. A0012005W001 use environments by the braider carrier 102 and / or wire strand 104. However, the prebending device 100 as shown has a carrier block 112 which is configured to reciprocate responsive to at least one of a spring-bias force (for motion towards the first rail and 108) and a pulling force from the braiding machine (e.g., from the braider carrier 102), exerted upon the braider carrier 102 via the wire strand 104. The spring-bias force of the prebending device 100 may be imparted on the carrier block 112 via a compression spring 132 extending longitudinally between the carrier block 112 and a second support bracket 134 located at the second rail end 110. Reciprocation of the carrier block 112 may help to avoid tangling of the wire strand 104 after it leaves the idler wheel 116 and / or to pull the wire strand 104 against at least one idler wheel 116.

[0053] More specifically, the compression spring 132 may be maintained in contact with at least one of the carrier block 112 and the second support bracket 134 (pushing the two mutually apart) by a spring retention rod 136 extending at least partially through at least one of the carrier block 112 and the second support bracket 134. That is, the spring retention rod 136 could extend through a longitudinal center of the compression spring 132 to prevent the compression spring 132 from buckling or separating from other portions of the prebending device 100 in an undesirable manner. The spring retention rod 136, when present, could serve as a guide rail in addition to assisting with guidance and maintenance of the compression spring 132 as described.

[0054] During use of the braiding machine, at least one chosen braider carrier, such as the example shown schematically in the Figures at 102, is controlled in a known manner to spin, rotate, precess, and / or otherwise move, optionally in coordination with at least one other braider carrier (not shown) to generate a desired braided structure in a known manner. The prebending device 100 is maintained in operative engagement with the at least one chosen braider carrier 102 of the braiding machine in order to prebend, prestress, tension, at least partially straighten, at least partially curl, or otherwise change at least one material characteristic of the wire strand 104 being directed from a feed spool 114 to the braided structure or product by the chosen braider carrier 102. It is contemplated that each braider carrier 102 of a braiding machine may have an associated prebending device 100; alternatively, at least one chosen braider carrier 102 could be provided with a prebendingDocket No. A0012005W001 device 100 in order to achieve desired configuration properties of only an associated wire strand 104 of the desired braided structure. For most use environments of the prebending device 100, though, the prebending device 100 will be firmly attached to the at least one chosen braider carrier 102, for collective motion in what could be a rather intricate travel path to achieve a desired braiding pattern.

[0055] For selectively attaching the prebending device 100 to the braider carrier 102, a carrier mount (shown schematically at 138) could be provided. The carrier mount 138 shown in at least Figs. 1-13 includes longitudinally spaced first and second support brackets 140 and 134, which are connected respectively to the first and second rail ends 108 and 110 of the at least one guide rail 106. As noted above, the second support bracket 134 may also serve a function by providing the compression spring 132 with a surface to push against and responsively bias the carrier block 112 toward the first rail end 108. The first and second support brackets 140 and 134 may assist with spacing and maintaining a plurality of guide rails 106 in a desired configuration for supporting reciprocal motion of the carrier block 112. Additionally, however, the first and second support brackets 140 and 134 may be connected to the braider carrier 102 for travel therewith during operation of a braiding device or machine incorporating the braider carrier 102.

[0056] The first and second support brackets 140 and 134 could be simply fastened to a suitable structure of the braider carrier 102. However, for many use environments, it may be desirable to provide the carrier mount 138 with a clamping plate 142 having first and second longitudinally spaced plate ends 144 and 146, respectively. The first and second support brackets 140 and 134 may be selectively attached, directly or indirectly, to the first and second plate ends 144 and 146, respectively. This may be accomplished via at least one or other fastener located at each of the first and second plate ends 144 and 146, as shown in Figs. 1-13, and / or in any desirable manner. At least a portion of the braider carrier 102 may be interposed laterally and / or transversely between at least a portion of the clamping plate 142 and the first and second support brackets 140 and 134, to affix the prebending device 100 to the braider carrier 102 in a secure manner, particularly considering the significant centrifugal forces which can be developed on the braider carrier 102 during operation of the braiding machine.Docket No. A0012005W001

[0057] Figs. 15-19 illustrate a second embodiment of a prebending device 100’. The prebending device 100’ of Figs. 15-19 is similar to the prebending device 100 of Figs. 1-13 and therefore, structures of Figs. 15-19 that are the same as or similar to those described with reference to Figs. 1-13 have the same reference numbers with the addition of a “prime” mark. Description of common elements and operation similar to those in the previously described first embodiment will not be repeated with respect to the second embodiment, but should instead be considered to be incorporated below by reference as appropriate.

[0058] As shown in Figs. 15-19, the at least one guide rail of the second embodiment of the prebending device 100’ is a single guide rail 106’. The carrier block 112’ slidably engages with the single guide rail 106’ via a carriage 148 fixedly attached to the carrier block 112’. For example, the carriage 148 could include ball bearing rollers (not shown) or any other features as desired to facilitate desired reciprocal sliding motion of the carrier block 112’ along at least one guide rail 106’ for a particular use environment, including predetermined rolling resistance, smooth travel and / or direction change, and / or any other physical properties or characteristics as desired. To facilitate desired sliding motion without twisting about the longitudinal axis, the single guide rail 106’ of the second embodiment may also or instead include at least one guiding groove 150 for selective slidable engagement with at least a portion of the carriage 148. For example, and as shown particularly in Figs. 15-17. the carriage 148 may include a C-shaped “underhanging” structure for interfacing with two guiding grooves 150 on laterally opposite sides of the single guide rail 106’. One of ordinary skill in the art can readily configure a suitable guide rail 106’ and carrier block 112’ arrangement for a particular use environment of the prebending device 100’.

[0059] Also as shown in Figs. 15-19 as being another difference from the first embodiment of Figs. 1-13, the carrier mount (shown collectively at 138’) may include first and second longitudinally spaced clamping brackets 152 and 154, respectively. The first and second clamping brackets 152 and 154 are selectively attached to the first and second support brackets 140’ and 134’, respectively, with at least a portion of the braider carrier 102’ being interposed laterally between at least a portion of the first and second clamping brackets 152 and 154 and the corresponding first and second support brackets 140’ and 134’.Docket No. A0012005W001

[0060] For example, and as shown, the first and second clamping brackets 152 and 154 could be hingedly attached to the first and second support brackets 140’ and 134’, and configured for “locking” or other securement thereto to prevent relative movement therebetween. In lieu of the clamping plate 142 of the first embodiment, the first and second clamping brackets 152 and 154 may be used to affix the prebending device 100’ of the second embodiment to the braider carrier 102’. This arrangement is shown in detail in Fig. 19.

[0061] As another option shown in Figs. 15-19 as incorporated into the second embodiment (but applicable to any embodiment), the spring retention rod 136’ may be threadably attached to at least one of the first and second support brackets 140’ and 134’, or to any other desired component of the prebending device 100’. As with the previously described prebending device 100 of the first embodiment, the spring retention rod 136’ of the second embodiment may be used to retain the compression spring 132’ in a linear manner to resist movement of the carrier block 112’ toward the second rail end 110’.

[0062] One of ordinary skill in the art, with reference to the description herein and the associated drawings, will readily be able to provide a prebending device 100 according to aspects of the present invention for use in a particular wire strand 104 braiding environment. Operation of such a prebending device 100 should likewise be apparent to that person of ordinary skill in the art, and may be modified as desired without departing from the teachings herein. However, one suitable example method of prebending a wire strand 104 for incorporation into at least one of a wire rope and a wire braid using the prebending device 100 described above will now be briefly summarized for the sake of description, without limiting application of the previously described structures and functions of the prebending device 100.

[0063] The wire strand 104 may be extended along a wire strand travel path (such as along the serpentine wire strand travel path P) between a feed spool 114 and a braider carrier 102. The carrier block 112, carrying the plurality of idler wheels 116, may be selectively slid longitudinally along at least one elongate guide rail 106. The carrier block 112 is spring- biased toward a first rail end 108 of the guide rail 106. By the plurality of idler wheels 116, at least two directional changes of at least ninety degrees each (e.g., between about 120 and 240 degrees each, or, more particularly, between about 150 and 213 degrees each) may be imparted to the serpentine portion of the wire strand travel path. Responsive to that spring-Docket No. A0012005W001 biased tension and / or to tension imparted naturally by other portions of the braider carrier 102 or braiding machine during passage of the wire strand 104 in contact with the at least one idler wheel 116, the wire strand 104 is formed to the predetermined wire bend radius via interaction with at least one idler wheel 116.

[0064] It is also contemplated that the wire strand 104 could be extended along a wire strand travel path (such as along the serpentine wire strand travel path P) between a feed spool 114 and a storage spool (not shown), instead of being sent straight to the braider carrier 102 or another component of a braiding machine. Accordingly, the wire strand 104 could be processed to have the predetermined wire bend radius and then stored for any desired length of time before being incorporated into a braided product.

[0065] It is contemplated that materials could be chosen, and / or a lubricating substance could be provided, to facilitate suitable slidable motion of the carrier block 112 along the guide rail(s) 106.

[0066] In summary, a person having ordinary skill in the art will understand that, alone or in combination with any other aspect, the present disclosure provides an example aspect 1 of a prebending device for selective attachment to a braider carrier and operative on a portion of a wire strand imposed operationally between a feed spool and the braider carrier. The prebending device comprises at least one elongate guide rail having longitudinally spaced first and second rail ends and being configured for selective attachment to the braider carrier. A carrier block is supported by the at least one guide rail for sliding movement therealong selectively at least partially between the first and second rail ends. The carrier block is spring-biased toward the first rail end. A plurality of idler wheels is concurrently carried by the carrier block. At least one idler wheel is rotatable about a wheel axis substantially perpendicular to the guide rail. The plurality of idler wheels collectively defines a serpentine wire strand travel path operationally between a wire entry point, from the feed spool, adjacent the first rail end and a wire exit point, toward the braider carrier, adjacent the second rail end / The serpentine wire strand travel path includes at least two directional changes, of at least ninety degrees each, collectively imparted by the plurality of idler wheels. A predetermined wire bend radius is imposed upon the wire strand responsive to interaction with at least one idler wheel.Docket No. A0012005W001

[0067] An example aspect 2 includes the prebending device of aspect 1, wherein the predetermined wire bend radius is imposed upon the wire strand responsive to at least one of a spring bias force imparted on the carrier block and an effective diameter of at least a chosen idler wheel.

[0068] An example aspect 3 includes the prebending device of any preceding aspect, wherein the wire strand is formed to the predetermined wire bend radius with at least one idler wheel responsive to at least one of spring-bias of the carrier block toward the first rail end and to tension imparted upon the wire strand by the braider carrier during passage of the wire strand in contact with the at least one idler wheel.

[0069] An example aspect 4 includes the prebending device of any preceding aspect, wherein the plurality of idler wheels includes at least one transition roller and at least one curler roller.

[0070] An example aspect 5 includes the prebending device of aspect 4, wherein at least a portion of the transition roller is positioned on the carrier block further toward the second rail end than is at least a portion of the curler roller.

[0071] An example aspect 6 includes the prebending device of aspect 4, wherein an entirety of the transition roller is positioned on the carrier block further toward the second rail end than is an entirety of the curler roller.

[0072] An example aspect 7 includes the prebending device of aspect 4, wherein the predetermined wire bend radius is imposed upon the wire strand responsive to an effective diameter of the curler roller.

[0073]

[0074] An example aspect 8 includes the prebending device of any of the preceding aspects, wherein the serpentine wire strand travel path includes a full rotational loop, when viewed in side profile.

[0075]

[0076] An example aspect 9 includes the prebending device of any of the preceding aspects, wherein at least one idler wheel has a spool shape, with two oppositely spaced outer flanges each having a larger diameter than a diameter of a barrel section interposed between the outer flanges.Docket No. A0012005W001

[0077] An example aspect 10 includes the prebending device of any of the preceding aspects, wherein the at least one guide rail includes first and second guide rails, and the carrier block includes a plurality of longitudinal through-holes, each of the first and second guide rails extending through a selected through-hole to support the carrier block for longitudinal sliding motion with respect to the first and second guide rails.

[0078] An example aspect 11 includes the prebending device of any of aspects 1 -9, wherein the at least one guide rail is a single guide rail, and the carrier block slidably engages with the single guide rail via a carriage fixedly attached to the carrier block.

[0079] An example aspect 12 includes the prebending device of aspect 11, wherein the single guide rail includes at least one guiding groove for selective slidable engagement with the carriage.

[0080] An example aspect 13 includes the prebending device of aspect 9, wherein the outer flanges taper inward to direct the wire strand toward the barrel section of the idler wheel.

[0081] An example aspect 14 includes the prebending device of any of the preceding aspects, wherein the serpentine wire strand travel path includes at least two directional changes, of between about 120 and 240 degrees each, collectively imparted by the plurality of idler wheels.

[0082] An example aspect 15 includes the prebending device of any of the preceding aspects, including a carrier mount for selectively attaching the prebending device to the braider carrier.

[0083] An example aspect 16 includes the prebending device of aspect 15, wherein the carrier mount includes longitudinally spaced first and second support brackets connected respectively to the first and second rail ends of the at least one guide rail, the first and second support brackets being connected to the braider carrier for travel therewith during operation of a braiding device incorporating the braider carrier.

[0084] An example aspect 17 includes the prebending device of aspect 16, wherein the carrier mount includes a clamping plate having first and second longitudinally spaced plate ends, the first and second support brackets being selectively attached to the first and second plate ends, respectively, with at least a portion of the braider carrier being interposed laterally between at least a portion of the clamping plate and the first and second support brackets, to affix the prebending device to the braider carrier.Docket No. A0012005W001

[0085] An example aspect 18 includes the prebending device of aspect 16, wherein the carrier mount includes first and second longitudinally spaced clamping brackets, the first and second clamping brackets being selectively attached to the first and second support brackets, respectively, with at least a portion of the braider carrier being interposed laterally between at least a portion of the first and second clamping brackets and the corresponding first and second support brackets, to affix the prebending device to the braider carrier.

[0086] An example aspect 19 includes the prebending device of any of the preceding aspects, wherein the at least one idler wheel is rotationally attached to the carrier block by an axle pin extending collinearly with the wheel axis, the axle pin extending at least partially through an arbor of the idler wheel.

[0087] An example aspect 20 includes the prebending device of any of the preceding aspects, wherein the spring-bias force is imparted on the carrier block via a compression spring extending longitudinally between the carrier block and a second support bracket located at the second rail end, the compression spring being maintained in contact with at least one of the carrier block and the second support bracket by a spring retention rod extending at least partially through the carrier block and the second support bracket.

[0088] An example aspect 21 includes the prebending device of aspect 20, wherein the spring retention rod is threadably attached to at least one of the first and second support brackets.

[0089] Additionally, a person having ordinary skill in the art will understand that, alone or in combination with any other aspect, the present disclosure provides an example aspect 22 of a method of prebending a wire strand for incorporation into at least one of a wire rope and a wire braid, the method comprising:

[0090] extending the wire strand along a wire strand travel path between a feed spool and a braider carrier;

[0091] providing a plurality of idler wheels, at least one idler wheel being rotatable about a wheel axis substantially perpendicular to the wire strand travel path;

[0092] concurrently carrying the plurality of idler wheels on a carrier block;

[0093] selectively sliding the carrier block, carrying the plurality of idler wheels, longitudinally along at least one elongate guide rail;

[0094] selectively attaching the guide rail to the braider carrier;Docket No. A0012005W001

[0095] spring-biasing the carrier block toward a first rail end of the guide rail;

[0096] collectively defining, with the plurality of idler wheels, a serpentine portion of the wire strand travel path interposed operationally between a wire entry point, from the feed spool, adjacent the first rail end and a wire exit point, toward the braider carrier, adjacent the second rail end;

[0097] imparting, by the plurality of idler wheels, in the serpentine portion of the wire strand travel path at least two directional changes of at least ninety degrees each; and

[0098] imposing a predetermined wire bend radius upon the wire strand responsive to interaction of the wire strand with at least one idler wheel.

[0099] An example aspect 23 includes the method of aspect 22, wherein imposing a predetermined wire bend radius upon the wire strand includes imposing the predetermined wire bend radius upon the wire strand responsive to at least one of a spring bias force imparted on the carrier block and an effective diameter of at least a chosen idler wheel.

[0100] An example aspect 24 includes the prebending device of any of aspects 22-23, wherein imposing a predetermined wire bend radius upon the wire strand includes forming the wire strand to the predetermined wire bend radius with at least one idler wheel responsive to at least one of spring-bias of the carrier block toward the first rail end and to tension imparted upon the wire strand by the braider carrier during passage of the wire strand in contact with the at least one idler wheel.

[0101] An example aspect 25 includes the method of any of aspects 22-24, wherein collectively defining, with the plurality of idler wheels, a serpentine portion of the wire strand travel path including collectively defining the serpentine wire strand travel path as including a full rotational loop, when viewed in side profile.

[0102] An example aspect 26 includes the method of any of aspects 22-25, wherein at least one idler wheel has a spool shape, with two oppositely spaced outer flanges each having a larger diameter than a diameter of a barrel section interposed between the outer flanges, and including the step of directing the wire strand toward the barrel section of the idler wheel.

[0103] An example aspect 27 includes the method of any of aspects 22-26, wherein the step of imparting, by the plurality of idler wheels, in the serpentine portion of the wire strand travel path at least two directional changes of at least ninety degrees each includes imparting,Docket No. A0012005W001 by the plurality of idler wheels, in the serpentine wire strand travel path at least two directional changes of between 120 and 240 degrees each.

[0104] An example aspect 28 includes the method of any of aspects 22-26, including:

[0105] selectively attaching the prebending device to the braider carrier with a carrier mount, the carrier mount including longitudinally spaced first and second support brackets connected respectively to the first and second rail ends of the at least one guide rail; and

[0106] wherein operation of a braiding device incorporating the braider carrier includes travel of the prebending device along with the braider carrier via connection of the first and second support brackets thereto.

[0107] An example aspect 29 includes the method of any of aspects 22-28, wherein selectively sliding the carrier block, carrying the plurality of idler wheels, longitudinally along at least one elongate guide rail includes:

[0108] imparting a spring-bias force on the carrier block via a compression spring extending longitudinally between the carrier block and a second support bracket located at the second rail end; and

[0109] maintaining the compression spring in contact with at least one of the carrier block and the second support bracket by a spring retention rod extending at least partially through the carrier block and the second support bracket.

[0110] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which the present disclosure pertains.

[0111] While aspects of this disclosure have been particularly shown and described with reference to the example aspects above, it will be understood by those of ordinary skill in the art that various additional aspects may be contemplated. For example, the specific methods described above for using the apparatus are merely illustrative; one of ordinary skill in the art could readily determine any number of tools, sequences of steps, or other means / options for placing the above-described apparatus, or components thereof, into positions substantively similar to those shown and described herein. In an effort to maintain clarity in the Figures, certain ones of duplicative components shown have not been specifically numbered, but one of ordinary skill in the art will realize, based upon the components that were numbered, theDocket No. A0012005W001 element numbers which should be associated with the unnumbered components; no differentiation between similar components is intended or implied solely by the presence or absence of an element number in the Figures. Any of the described structures and components could be integrally formed as a single unitary or monolithic piece or made up of separate sub-components, with either of these formations involving any suitable stock or bespoke components and / or any suitable material or combinations of materials. Any of the described structures and components could be disposable or reusable as desired for a particular use environment. Any component could be provided with a user-perceptible marking to indicate a material, configuration, at least one dimension, or the like pertaining to that component, the user-perceptible marking potentially aiding a user in selecting one component from an array of similar components for a particular use environment. A “predetermined” status may be determined at any time before the structures being manipulated actually reach that status, the “predetermination” being made as late as immediately before the structure achieves the predetermined status. The term “substantially” is used herein to indicate a quality that is largely, but not necessarily wholly, that which is specified— a “substantial” quality admits of the potential for some relatively minor inclusion of a non-quality item. Though certain components described herein are shown as having specific geometric shapes, all structures of this disclosure may have any suitable shapes, sizes, configurations, relative relationships, cross-sectional areas, or any other physical characteristics as desirable for a particular application. Any structures or features described with reference to one aspect or configuration could be provided, singly or in combination with other structures or features, to any other aspect or configuration, as it would be impractical to describe each of the aspects and configurations discussed herein as having all of the options discussed with respect to all of the other aspects and configurations. A device or method incorporating any of these features should be understood to fall under the scope of this disclosure as determined based upon the claims below and any equivalents thereof.

[0112] Other aspects, objects, and advantages can be obtained from a study of the drawings, the disclosure, and the appended claims.

Claims

Docket No. A0012005W001WHAT IS CLAIMED IS:

1. A prebending device for selective attachment to a braider carrier and operative on a portion of a wire strand imposed operationally between a feed spool and the braider carrier, the prebending device comprising: at least one elongate guide rail having longitudinally spaced first and second rail ends and being configured for selective attachment to the braider carrier; a carrier block supported by the at least one guide rail for sliding movement therealong selectively at least partially between the first and second rail ends, the carrier block being spring-biased toward the first rail end; and a plurality of idler wheels concurrently carried by the carrier block, at least one idler wheel being rotatable about a wheel axis substantially perpendicular to the guide rail, the plurality of idler wheels collectively defining a serpentine wire strand travel path operationally between a wire entry point, from the feed spool, adjacent the first rail end and a wire exit point, toward the braider carrier, adjacent the second rail end; wherein the serpentine wire strand travel path includes at least two directional changes, of at least ninety degrees each, collectively imparted by the plurality of idler wheels; and wherein a predetermined wire bend radius is imposed upon the wire strand responsive to interaction with at least one idler wheel.

2. The prebending device of claim 1, wherein the predetermined wire bend radius is imposed upon the wire strand responsive to at least one of a spring bias force imparted on the carrier block and an effective diameter of at least a chosen idler wheel.

3. The prebending device of any preceding claim, wherein the wire strand is formed to the predetermined wire bend radius with at least one idler wheel responsive to at least one of spring-bias of the carrier block toward the first rail end and to tension imparted upon the wire strand by the braider carrier during passage of the wire strand in contact with the at least one idler wheel.Docket No. A0012005W0014. The prebending device of any of the preceding claims, wherein the serpentine wire strand travel path includes a full rotational loop, when viewed in side profile.

5. The prebending device of any of the preceding claims, wherein at least one idler wheel has a spool shape, with two oppositely spaced outer flanges each having a larger diameter than a diameter of a barrel section interposed between the outer flanges.

6. The prebending device of any of the preceding claims, wherein the at least one guide rail includes first and second guide rails, and the carrier block includes a plurality of longitudinal through-holes, each of the first and second guide rails extending through a selected through-hole to support the carrier block for longitudinal sliding motion with respect to the first and second guide rails.

7. The prebending device of any of claims 1-5, wherein the at least one guide rail is a single guide rail, and the carrier block slidably engages with the single guide rail via a carriage fixedly attached to the carrier block.

8. The prebending device of any of the preceding claims, wherein the serpentine wire strand travel path includes at least two directional changes, of between about 120 and 240 degrees each, collectively imparted by the plurality of idler wheels.

9. The prebending device of any of the preceding claims, including a carrier mount for selectively attaching the prebending device to the braider carrier.

10. The prebending device of any of the preceding claims, wherein the spring-bias force is imparted on the carrier block via a compression spring extending longitudinally between the carrier block and a second support bracket located at the second rail end, the compression spring being maintained in contact with at least one of the carrier block and the second support bracket by a spring retention rod extending at least partially through the carrier block and the second support bracket.Docket No. A0012005W00111. A method of prebending a wire strand for incorporation into at least one of a wire rope and a wire braid, the method comprising: extending the wire strand along a wire strand travel path between a feed spool and a braider carrier; providing a plurality of idler wheels, at least one idler wheel being rotatable about a wheel axis substantially perpendicular to the wire strand travel path; concurrently carrying the plurality of idler wheels on a carrier block; selectively sliding the carrier block, carrying the plurality of idler wheels, longitudinally along at least one elongate guide rail; selectively attaching the guide rail to the braider carrier; spring-biasing the carrier block toward a first rail end of the guide rail; collectively defining, with the plurality of idler wheels, a serpentine portion of the wire strand travel path interposed operationally between a wire entry point, from the feed spool, adjacent the first rail end and a wire exit point, toward the braider carrier, adjacent the second rail end; imparting, by the plurality of idler wheels, in the serpentine portion of the wire strand travel path at least two directional changes of at least ninety degrees each; and imposing a predetermined wire bend radius upon the wire strand responsive to interaction of the wire strand with at least one idler wheel.

12. The method of claim 11, wherein imposing a predetermined wire bend radius upon the wire strand includes imposing the predetermined wire bend radius upon the wire strand responsive to at least one of a spring bias force imparted on the carrier block and an effective diameter of at least a chosen idler wheel.

13. The method of any of claims 11-12, wherein collectively defining, with the plurality of idler wheels, a serpentine portion of the wire strand travel path including collectively defining the serpentine wire strand travel path as including a full rotational loop, when viewed in side profile.Docket No. A0012005W00114. The method of any of claims 11-13, wherein the step of imparting, by the plurality of idler wheels, in the serpentine portion of the wire strand travel path at least two directional changes of at least ninety degrees each includes imparting, by the plurality of idler wheels, in the serpentine wire strand travel path at least two directional changes of between 120 and 240 degrees each.

15. The method of any of claims 11-14, including: selectively attaching the prebending device to the braider carrier with a carrier mount, the carrier mount including longitudinally spaced first and second support brackets connected respectively to the first and second rail ends of the at least one guide rail; and wherein operation of a braiding device incorporating the braider carrier includes travel of the prebending device along with the braider carrier via connection of the first and second support brackets thereto.

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