US3112226A - Apparatus for coating wire - Google Patents

Apparatus for coating wire Download PDF

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Publication number
US3112226A
US3112226A US36799A US3679960A US3112226A US 3112226 A US3112226 A US 3112226A US 36799 A US36799 A US 36799A US 3679960 A US3679960 A US 3679960A US 3112226 A US3112226 A US 3112226A
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tube
coating
chamber
wire
bath
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US36799A
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Jean Robert R St
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Worcester Automatic Machine Co
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Worcester Automatic Machine Co
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
    • C23C2/36—Elongated material
    • C23C2/38—Wires; Tubes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S118/00—Coating apparatus
    • Y10S118/19—Wire and cord immersion

Definitions

  • This invention relates to an apparatus for coa-ting wire. More particularly, the invention relates to an improved apparatus for coating wire with a thin uniform coating of closely controlled thickness bonded thereto.
  • a wire coated with a uniform thin metal coating the coated product having not only an accurately controlled overall diameter, but the coating being closely controlled as to thickness.
  • An example of such wire is tinned or solder coated copper wire for use as electrical conductors in radios and the like.
  • the solder coating on such wire is such that junctions between wires so coated can be made by heating and pressing the wires -together without the neces-sity of any additional solder.
  • the best quality wire of this type must have a solder coating of uniform thickness, and the coating must be free from pin holes and inclusions.
  • the outer diameter of the wire must be held to very close tolerances of accuracy if the product is -to be satisfactory.
  • the invention has among its objects the provision of a novel apparatus for coating metal cores of thin gauge with continuous thin uniform coatings.
  • a further object of the invention lies in the provision of an improved apparatus for continuously coating a wire core with a thin accurate metal coating of la metal having a melting point lower than that of the core.
  • Yet another object of the invention lies in the provision of an improved apparatus for producing a thin metal coating on wire, the product of such apparatus being particularly characterized by the accuracy of the thickness of the coating, the accuracy of the outer diameter of the coated wire, the perfection of the bond of the coating to the wire core, and the freedom of the coating from pin holes, oxide inclusions, and the like.
  • FIG. 1 is a View in transverse section through a typical coated wire made by the method and apparatus of the invention
  • FIG. 2 is a schematic View partially in section and partially in elevation of a complete wire coating organization, including the improved apparatus of the invention
  • PIG. 3 is an enlarged View in vertical cross section through the metal coating pot of the apparatus and a portion of the die-forming, protecting, and coatingsmoothing tube associated therewith, certain of the parts being shown in elevation;
  • FIG. 4 is .a fragmentary View on a still greater scale of enlargement of the upper end portion of the wire-coating tube associated with the coating pot;
  • ice IFIG. 5 is a still further enlarged fragmentary schematic view in vertical axial section through the wirecoating tube in the vicinity of the location where the coating metal on the wire begins to solidify, the section being taken generally along the line 5-5 of FIG. 3.
  • FIG. l there is shown in FlG. l -a typical coated wire 12 having a circular cylindrical core 1i? and a thin solder coating 11 bonded thereto.
  • a typical coated wire treated in accordance with the invention is one having a copper core with la diameter of .030" with a uniform solder coating there-about having a thickness of .005.
  • Such product ⁇ for some uses must be held ⁇ accurateiy to an overall diameter of .040, and must have coating 11 free from pin holes and the 4like and held within a close tolerance of accuracy as to the thickness.
  • Uncoated wire 10 is fed from a supply reel 14 over a guide roll 1S and thence into an acid cleaning or pickling bath 16 held in a pickling pan 17.
  • the wire Upon emerging from pan 17 the wire travels upwardly to a guide roller 19 ⁇ which is disposed vertically Iabove a coating pot 20. From roller 19 the wire travels downwardly, as shown, into the molten metal 24 in the coating pot and thence into the upper end of a die-forming, protecting, and smoothing tube 3o, to be described in detail hereinafter.
  • the then coated and at least partially cooled wire is led around a further guide roller ⁇ 52, upwardly to roller 54, yand to a take-up reel 56.
  • the take-up apparatus is preferably provided with a levelwind device, schematically shown at 57.
  • the described wire traversing system is such as to pull the wire at a controlled constant speed through the coating apparatus.
  • Guide rollers 19 and S2 are accurately positioned so as to aid in centering wire in the die-forming and smoothing tube 36.
  • the structure of the die-forming protecting and smoothing tube of the invention, and of the metal coating pot in which it is mounted, is shown more particularly in FIGS. 3 and 4.
  • the lpot 20' has an inner solder cases 21 and an outer heat insulating case 22.
  • T he relatively low melting point coating metal, such as solder 2e, is held in molten condition at substantially constant temperature, as by a thermostatically controlled electric heater 25 of the immersion type.
  • an upstanding hollow tubing guide 26 Mounted on the bottom wall of solder case 21 is an upstanding hollow tubing guide 26.
  • Guide 26 has the lower end thereof protruding downwardly through an opening 27 in the bottom of the solder case, an annular flange 29 on member 26 forcibly engaging the annular zone around the opening 27 through the bottom of the oase.
  • Member 26 is held in position by means of -a check nut 31 disposed beneath the bottom wall of case 21 and having screw threaded engagement with the threaded lower end 30' of member 26.
  • a thin steel tube 134 is snugly and sealingly engaged within the central passage 35 in tubing guide 26.
  • Tube 34 extends upwardly within member 26 just short of the upper end thereof, and extends downwardly below the lower end of member 26 through the zone 34 wherein it is exposed to the atmosphere (FIG. 2) and the further zone 34" wherein it lies within a cooling jacket ⁇ t2, to be described.
  • Tube 34 forms an outer strengthening jacket for the inner die-forming, protecting, and smoothing tube proper, designated by the character 36.
  • Tube 36 has a flared upper end 37 which both facilitates the initial entry of a wire thereinto and also tits ywithin the flared upper end 39 of passage 35 in member 26, thereby to prevent lthe escape of tube 36 from tube 34 and member 26.
  • the outer tube 34, with the inner tube 36 telescoped therev.” hin is held within member 26 by a packing gland 4l through which the assembled tubes extend.
  • Gland 41 is screwed into the counterbored lower end of member Z6, and serves to compress packing material 4G located within the joint between such members.
  • the tubes extend into a cooling jacket 42 where they are subjected to a shower of cooling water delivered to the upper end of the jacket through a pipe 44.
  • a shower of cooling water delivered to the upper end of the jacket through a pipe 44.
  • Such water may be from any source desired and may, if necessary, be controlled as to temperature so that the coating on the coated wire l2 has become fully solidified by the time the coated Wire emerges from the lower end of tube 36.
  • a sump device such as an open topped tank 47 in which there is held a substantial quantity of water 49 which has fallen from the exhaust openings G of the cooling jacket.
  • Water 49 is, in the embodiment shown, continuously supplied to pipe 44 through the medium of pump 45 and the feed pipe 46 leading from the sump to the pump. It is preferred that at least some of the cooling fvvater discharged from the cooling jacket shall impinge upon the lower guide roll 52 as shown so as to maintain its temperature Well below the melting point of coating metal i1.
  • the thin protective tube 34 is in that Zone provided with a substantial number of small openings 51 therethrough, so 4that the cooling water may directly contact the outer surface of inner tube 36 at such locations.
  • the tube 36 is made of a high temperature resistant plastic mate-
  • rial such as polytetrauoroethylene.
  • tube 36 can be made is polychlorotriliuoroethylene such as that sold under the trademarks Kel-F or that sold under the trademark lFluorothene
  • the upper end of tube 36 is disposed at a substantial depth l-l below the top of the bath of molten solder 2l.
  • H is maintained at approximately 4 inches.
  • the solder thus possesses a substantial hydrostatic head at the upper, entrance end of tube 36. It is believed that in its initial passage downwardly through bath 2l before entering tube 36 the wire core l@ becomes substantially completely wet by the molten solder. The appreciable downward speed of the wire core tends to draw molten solder along with it into the tube 36. By reason of such motion of the core, as well as capillary action because of the small clearance between the core and the bore 38 through tube 36, the core tends to center itself in such passage and thus to form a coating of uniform thickness around the core.
  • the coating on the core shall remain substantially molten throughout an appreciable length of travel of the wire in order to penfect the bond between the coating and the core. For this reason it is preferred that the first section 34 of the assembled tubes 36 and be exposed to the atmosphere, as shown, so that the rate of cooling of the product in such zone is slow.
  • the coating is then cooled more rapidly by the cooling jacket 42, functioning as above described. ln the initial part of zone 34, wherein the coating begins to congeal but is still plastic, the tube 36 serves to smooth and finally dimension the coating.
  • the tube 36 functions as a die, as a protective sleeve, and as a coating-smoothing and dimensioning means. Throughout the entire length of travel of the wire from the time it enters coating bath 21 to the ⁇ tin e it emerges from the lower end of tube 36 the wire is completely shielded from the atmosphere, and thus cannot become oxidized while the coating is being formed on the core or while the core is being solidified and smoothed.
  • Such combined actions of the tube 36, plus the fact that the wire is engaged by one continuous smooth surface throughout the length of tube 36, are at least in part responsible for the perfection of the product obtained by use of the invention.
  • the tube 36 snugly embraces inner tube 36 and holds the passage 38 therewithin to close tolerances of accuracy as to diameter and straightness. It is to be understood that, in some instances where the material of which tube 36 possesses suliicient strength and dimensional stability to maintain its bore diameter and straightness without reinforcement, tube 34 may be dispensed with.
  • the apparatus of the invention is further advantageous, because it may readily be strung ⁇ with Wire 10 at the beginning of a run and may be left at least temporarily with no wire 1G strung therethrough without damage to any of the parts.
  • the tube 34 As indicated in phantom lines in FIG. 3, wherein the tube 34 is there designated 341, the tube may be raised so that its upper end 3'7 lies above the top of the bath 24 of molten metal.
  • Such raising of the tube may be eflected as by providing a bracket, not shown, surrounding the upper end 37 of the tube, such bracket having a handle which projects upwardly through the molten metal 24 and over an upper edge of the pot 20.
  • the tube 34 By pulling on such handle the tube 34 may be raised into the position 341, whereby to facilitate the Stringing of wire l@ therethrough, or to prevent the escape of molten metal downwardly through the tube when no wire 10 is passing therethrough.
  • Apparatus for applying and bonding a thin iinpervious coating to a continuous elongated metal core comprising a chamber adapted ⁇ to contain a bath of molten coating material, means to maintain the bath at elevated temperature, an elongated generally vertically disposed tube extending downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform throughout its length from substantially its upper to its lower end and equal to the outer diameter of the tinished coated product, the upper end of the tube being open to the interior of the chamber below the top of the molten material in the chamber, the tube extending a substantial distance below the chamber, means continuously to pull the core down through the molten bath of coating material, into the upper end of the tube, and ⁇ through the tube, and means to cool the tube at a location below the chamber whereby to solidify the coating and cool the coated product, the 4tube having an inner surface made of heat resistant plastic material to which the coating material does not stick during its passage therethrough, the inner surface of the tube consisting of a material selected from
  • Apparatus for applying and bonding a thin impervious coating to a continuous elongated .metal core comprising a chamber adapted to contain a bath of molten coating material, means to maintain the bath at elevated temperature, an elongated generally vertically disposed tube extending downwardly from the bottom of the charnber, the inner diameter of the tube being uniform throughout its length from substantially its upper toits lower end and equal to the outer diameter of the finished coated product, the upper end of the tube being open to the interior of the chamber and lying appreciably below the top of lthe molten material in the chamber, the tube extending a substantial distance below the chamber, means continuously to pull the core down through the molten bath of coating material, into .the upper end of the tube, and through the tube, the exterior of the tube being exposed to the atmosphere for a substantial distance below the bottom of the chamber, and means to cool the tube at a location below the exposed zone thereof, whereby to solidify the coating and cool the coated product, the inner surface of the tube being made of heat resistant
  • Apparatus for lapplying and bonding a thin impervious metal coating to a continuous elongated metal wire of higher mel-ting point metal comprising a chamber adapted to contain a bath of molten coating metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending a substantial distance downwardly from the bottom of the chamber, the inner diameter ⁇ of the tube being substantially uniform throughout the predominant pant of its length and equal to the outer diameter of the finished coated product, the upper end of the tube being open to the interior of the chamber and extending a substantial distance upwardly into the bath of molten metal but lying a substantial distance bel-ow ⁇ the top of the bath, the tube having a continuous inner surface made of heat resistance material to which the coating material does not stick during its passage therethrough, means to guide the wire in its travel down through the molten metal bath into the upper end of the tube, into the upper end of the tube, and through 4the tube, the tube having ⁇ a tirst zone of substantial length below and
  • Apparatus for applying and bonding a thin impervious low melting point metal coating to a continuous elongated cylindrical metal wire ⁇ of higher melting point metal comprising a chamber adapted to contain ⁇ a bath of molten coa-ting metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending a substantial distance downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform from substantially its upper to its lower end and equal to the outer diameter of the finished coated product, the upper end of the tube being open to the interior of the chamber and extending a substantial distance upwardly into the bath of molten metal but lying a substantial distance below the top of the bath, the tube having a continuous inner LlO surface made of heat-resistant plastic material to which the coating material does not stick during its passage therethrough, means to guide the wire in its travel down through the molten metal bath into the upper end of the tube, into the upper end of the tube, and through the tube, the tube having -a iirst zone
  • Apparatus -ior applying and bonding a thin impervious metal coating to a continuous elongated metal wire of higher melting point metal comprising a chamber adapted to contain a bath of molten ⁇ coating metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform throughout the predominant part of its length and equal to the outer diameter of the nished ⁇ coated product, the upper end of the tube being7 open to the interior of the chamber and extending a substantial distance upwardly into the bath of molten metal but lying a ⁇ substantial distance below the top of the bath, the tube having a continuous inner surface made of heat resistant plastic material to which the coating material does not stick during its passage therethrough, means to guide and continuously pull the wire at substantially constant speed down through the molten metal bath, into the upper end of the tube, and through the tube, the tube being exposed to the atmosphere for a substantial distance below the bottom of the chamber, and
  • Apparatus for applying and bonding la thin impervious low melting point metal coa-ting to a continuous elongated cylindrical metal wire of higher melting point metal comprising a chamber adapted to contain a bath of molten coating metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform from substantially its upper to its lower end and equal to the outer diameter of the inished coated product, the upper end of the tube being open to the in-terior of the chamber and extending a substant-al distance upwardly into the bath of molten metal but lying a substantial distance below the top of the bath, the tube having a continuous inner surface made of heatresistant plastic material to which the coating material does not stick during its passage therethrough, means to guide and continuously pull the wire rat substantially constant speed down through the molten metal bath, into the upper end iot the tube, and through the tube, the tube being exposed to the atmosphere -for a substantial distance below the bottom of

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating With Molten Metal (AREA)

Description

Nov. 26, 1963 R. R. sT. JEAN 3,112,226
APPARATUS FOR COATING WIRE Filed June 17, 1960 2 Sheets-Sheet 1 ROBERT R. ST. JEAN BY @fd/z ma.,
ATTORNEY Nov. 26, 1963 R. R` sT. JEAN 3,112,226
APPARATUS FOR COATING WIRE Filed June 17, Y1960 2 Sheets-Sheet 2 30 54' y al l2 ATTORNEY United States Patent O 3,112,226 APPARATUS FR CATHNG WERE Robert R. St. Jean, Auburn, Mass., assigner to Worcester Automatic Machine Company, Worcester, Mass., a corporation of Massachusetts Filed June 17, 195i), Ser. No. 36,799 7 Ciaims. Cl. 11S-die) This invention relates to an apparatus for coa-ting wire. More particularly, the invention relates to an improved apparatus for coating wire with a thin uniform coating of closely controlled thickness bonded thereto.
There is `a substantial need in the industry for a wire coated with a uniform thin metal coating, the coated product having not only an accurately controlled overall diameter, but the coating being closely controlled as to thickness. An example of such wire is tinned or solder coated copper wire for use as electrical conductors in radios and the like. The solder coating on such wire is such that junctions between wires so coated can be made by heating and pressing the wires -together without the neces-sity of any additional solder. The best quality wire of this type must have a solder coating of uniform thickness, and the coating must be free from pin holes and inclusions. In addition, the outer diameter of the wire must be held to very close tolerances of accuracy if the product is -to be satisfactory.
It was quite diicult, by use of prior existing coating apparatus and methods to produce a satisfactory product at `a commercially feasible rate. Usually the amount of product rejected upon inspection was high, so that not only was the acceptable product markedly increased in cost but -the yamount of waste was unduly high.
The invention has among its objects the provision of a novel apparatus for coating metal cores of thin gauge with continuous thin uniform coatings.
A further object of the invention lies in the provision of an improved apparatus for continuously coating a wire core with a thin accurate metal coating of la metal having a melting point lower than that of the core.
Yet another object of the invention lies in the provision of an improved apparatus for producing a thin metal coating on wire, the product of such apparatus being particularly characterized by the accuracy of the thickness of the coating, the accuracy of the outer diameter of the coated wire, the perfection of the bond of the coating to the wire core, and the freedom of the coating from pin holes, oxide inclusions, and the like.
The above and further objects and novel features of the invention will more fully appear from the following description when the same is read in connection with the accompanying drawings. It is to be expressly understood, however, that the drawings are for the purpose of illustration only, and are not intended as a definition of the limits of the invention.
ln the drawings, wherein like reference characters refer to like parts throughout the several views,
FIG. 1 is a View in transverse section through a typical coated wire made by the method and apparatus of the invention;
FIG. 2 is a schematic View partially in section and partially in elevation of a complete wire coating organization, including the improved apparatus of the invention;
PIG. 3 is an enlarged View in vertical cross section through the metal coating pot of the apparatus and a portion of the die-forming, protecting, and coatingsmoothing tube associated therewith, certain of the parts being shown in elevation;
FIG. 4 is .a fragmentary View on a still greater scale of enlargement of the upper end portion of the wire-coating tube associated with the coating pot; and
iigii Patented Nov. 26, 1963 ice IFIG. 5 is a still further enlarged fragmentary schematic view in vertical axial section through the wirecoating tube in the vicinity of the location where the coating metal on the wire begins to solidify, the section being taken generally along the line 5-5 of FIG. 3.
Turning to the drawings, there is shown in FlG. l -a typical coated wire 12 having a circular cylindrical core 1i? and a thin solder coating 11 bonded thereto. A typical coated wire treated in accordance with the invention is one having a copper core with la diameter of .030" with a uniform solder coating there-about having a thickness of .005. Such product `for some uses must be held `accurateiy to an overall diameter of .040, and must have coating 11 free from pin holes and the 4like and held within a close tolerance of accuracy as to the thickness.
=It will be appreciated from such requirements that a completely satisfactory product of this type is hard to achieve.
Turning now to PIG. 2, there is there generally shown a complete wire coating organization of which the irnproved apparatus of the invention forms a part. Uncoated wire 10 is fed from a supply reel 14 over a guide roll 1S and thence into an acid cleaning or pickling bath 16 held in a pickling pan 17. Upon emerging from pan 17 the wire travels upwardly to a guide roller 19` which is disposed vertically Iabove a coating pot 20. From roller 19 the wire travels downwardly, as shown, into the molten metal 24 in the coating pot and thence into the upper end of a die-forming, protecting, and smoothing tube 3o, to be described in detail hereinafter. Upon emerging from the bottom end of tube 36 the then coated and at least partially cooled wire is led around a further guide roller `52, upwardly to roller 54, yand to a take-up reel 56. The take-up apparatus is preferably provided with a levelwind device, schematically shown at 57. The described wire traversing system is such as to pull the wire at a controlled constant speed through the coating apparatus. Guide rollers 19 and S2 are accurately positioned so as to aid in centering wire in the die-forming and smoothing tube 36.
The structure of the die-forming protecting and smoothing tube of the invention, and of the metal coating pot in which it is mounted, is shown more particularly in FIGS. 3 and 4. As there sshown, the lpot 20' has an inner solder cases 21 and an outer heat insulating case 22. T he relatively low melting point coating metal, such as solder 2e, is held in molten condition at substantially constant temperature, as by a thermostatically controlled electric heater 25 of the immersion type.
Mounted on the bottom wall of solder case 21 is an upstanding hollow tubing guide 26. Guide 26 has the lower end thereof protruding downwardly through an opening 27 in the bottom of the solder case, an annular flange 29 on member 26 forcibly engaging the annular zone around the opening 27 through the bottom of the oase. Member 26 is held in position by means of -a check nut 31 disposed beneath the bottom wall of case 21 and having screw threaded engagement with the threaded lower end 30' of member 26. A thin steel tube 134 is snugly and sealingly engaged within the central passage 35 in tubing guide 26. Tube 34 extends upwardly within member 26 just short of the upper end thereof, and extends downwardly below the lower end of member 26 through the zone 34 wherein it is exposed to the atmosphere (FIG. 2) and the further zone 34" wherein it lies within a cooling jacket `t2, to be described.
Tube 34 forms an outer strengthening jacket for the inner die-forming, protecting, and smoothing tube proper, designated by the character 36. Tube 36 has a flared upper end 37 which both facilitates the initial entry of a wire thereinto and also tits ywithin the flared upper end 39 of passage 35 in member 26, thereby to prevent lthe escape of tube 36 from tube 34 and member 26. rthe outer tube 34, with the inner tube 36 telescoped therev." hin, is held within member 26 by a packing gland 4l through which the assembled tubes extend. Gland 41 is screwed into the counterbored lower end of member Z6, and serves to compress packing material 4G located within the joint between such members.
As shown in FIG. 2, beyond the location at which the telescoped tubes 34 and 36 emerge from the lower end of member 26 they are exposed to the atmosphere at zone 34. From zone 34 the tubes extend into a cooling jacket 42 where they are subjected to a shower of cooling water delivered to the upper end of the jacket through a pipe 44. Such water may be from any source desired and may, if necessary, be controlled as to temperature so that the coating on the coated wire l2 has become fully solidified by the time the coated Wire emerges from the lower end of tube 36. Ordinarily it is preferred, in the interests of economy in the use of water, to employ a sump device such as an open topped tank 47 in which there is held a substantial quantity of water 49 which has fallen from the exhaust openings G of the cooling jacket. Water 49 is, in the embodiment shown, continuously supplied to pipe 44 through the medium of pump 45 and the feed pipe 46 leading from the sump to the pump. It is preferred that at least some of the cooling fvvater discharged from the cooling jacket shall impinge upon the lower guide roll 52 as shown so as to maintain its temperature Well below the melting point of coating metal i1. In order to make possible the more rapid abstraction of heat from tube 36 and the coated wire 12 passing therethrough in the zone 34", the thin protective tube 34 is in that Zone provided with a substantial number of small openings 51 therethrough, so 4that the cooling water may directly contact the outer surface of inner tube 36 at such locations.
In one preferred embodiment of the invention, the tube 36 is made of a high temperature resistant plastic mate- |rial such as polytetrauoroethylene. Not only does such material substantially retain its strength and durability despite its being heated for long periods to the temperature of molten solder 4(eg. 350-375 F. for a solder containing 2 parts lead and 5 parts of tin), but it displays nonsticking characteristics which aid in the passage of the coated product therethrough and in the smoothing and polishing of the coated product. It is to be understood that, within the scope of the invention, the tube 36 may be made of other materials displaying suitable resistance to the temperatures involved, dimensional stability, and surface characteristics such that the coated wire travels readily therethrough. Among such Iother materials of which tube 36 can be made is polychlorotriliuoroethylene such as that sold under the trademarks Kel-F or that sold under the trademark lFluorothene In accordance with the invention, the upper end of tube 36 is disposed at a substantial depth l-l below the top of the bath of molten solder 2l. In a preferred embodiment H is maintained at approximately 4 inches. The solder thus possesses a substantial hydrostatic head at the upper, entrance end of tube 36. It is believed that in its initial passage downwardly through bath 2l before entering tube 36 the wire core l@ becomes substantially completely wet by the molten solder. The appreciable downward speed of the wire core tends to draw molten solder along with it into the tube 36. By reason of such motion of the core, as well as capillary action because of the small clearance between the core and the bore 38 through tube 36, the core tends to center itself in such passage and thus to form a coating of uniform thickness around the core.
It is desired that the coating on the core shall remain substantially molten throughout an appreciable length of travel of the wire in order to penfect the bond between the coating and the core. For this reason it is preferred that the first section 34 of the assembled tubes 36 and be exposed to the atmosphere, as shown, so that the rate of cooling of the product in such zone is slow. In the further zone 34", below zone 34, after the coating has become well bonded to the core and the core has been entered in passage 38 in tube 36 by the coating, the coating is then cooled more rapidly by the cooling jacket 42, functioning as above described. ln the initial part of zone 34, wherein the coating begins to congeal but is still plastic, the tube 36 serves to smooth and finally dimension the coating.
The tube 36, as above indicated, functions as a die, as a protective sleeve, and as a coating-smoothing and dimensioning means. Throughout the entire length of travel of the wire from the time it enters coating bath 21 to the `tin e it emerges from the lower end of tube 36 the wire is completely shielded from the atmosphere, and thus cannot become oxidized while the coating is being formed on the core or while the core is being solidified and smoothed. Such combined actions of the tube 36, plus the fact that the wire is engaged by one continuous smooth surface throughout the length of tube 36, are at least in part responsible for the perfection of the product obtained by use of the invention. In the embodiment shown, the tube 36 snugly embraces inner tube 36 and holds the passage 38 therewithin to close tolerances of accuracy as to diameter and straightness. It is to be understood that, in some instances where the material of which tube 36 possesses suliicient strength and dimensional stability to maintain its bore diameter and straightness without reinforcement, tube 34 may be dispensed with.
The apparatus of the invention is further advantageous, because it may readily be strung `with Wire 10 at the beginning of a run and may be left at least temporarily with no wire 1G strung therethrough without damage to any of the parts. As indicated in phantom lines in FIG. 3, wherein the tube 34 is there designated 341, the tube may be raised so that its upper end 3'7 lies above the top of the bath 24 of molten metal. Such raising of the tube may be eflected as by providing a bracket, not shown, surrounding the upper end 37 of the tube, such bracket having a handle which projects upwardly through the molten metal 24 and over an upper edge of the pot 20. By pulling on such handle the tube 34 may be raised into the position 341, whereby to facilitate the Stringing of wire l@ therethrough, or to prevent the escape of molten metal downwardly through the tube when no wire 10 is passing therethrough.
Although only one embodiment of the invention has been illustrated in the accompanying drawings and described in the foregoing specification, it is to be especialiy understood that various changes, such as in the relative dimensions of the parts, materials used, and the like, as well as the suggested manner of use of the apparatus or the invention, may be made therein without departing from the spirit and scope of the invention as will now be apparent to those skilled in the art.
What is claimed is:
1. Apparatus for applying and bonding a thin iinpervious coating to a continuous elongated metal core, comprising a chamber adapted `to contain a bath of molten coating material, means to maintain the bath at elevated temperature, an elongated generally vertically disposed tube extending downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform throughout its length from substantially its upper to its lower end and equal to the outer diameter of the tinished coated product, the upper end of the tube being open to the interior of the chamber below the top of the molten material in the chamber, the tube extending a substantial distance below the chamber, means continuously to pull the core down through the molten bath of coating material, into the upper end of the tube, and `through the tube, and means to cool the tube at a location below the chamber whereby to solidify the coating and cool the coated product, the 4tube having an inner surface made of heat resistant plastic material to which the coating material does not stick during its passage therethrough, the inner surface of the tube consisting of a material selected from the group consisting of polytetrailuoroethylene and polychlorotriuoroethylene.
2. Apparatus as claimed in claim 1, wherein the plastic inner surface of the tube is continuous.
3. Apparatus for applying and bonding a thin impervious coating to a continuous elongated .metal core, comprising a chamber adapted to contain a bath of molten coating material, means to maintain the bath at elevated temperature, an elongated generally vertically disposed tube extending downwardly from the bottom of the charnber, the inner diameter of the tube being uniform throughout its length from substantially its upper toits lower end and equal to the outer diameter of the finished coated product, the upper end of the tube being open to the interior of the chamber and lying appreciably below the top of lthe molten material in the chamber, the tube extending a substantial distance below the chamber, means continuously to pull the core down through the molten bath of coating material, into .the upper end of the tube, and through the tube, the exterior of the tube being exposed to the atmosphere for a substantial distance below the bottom of the chamber, and means to cool the tube at a location below the exposed zone thereof, whereby to solidify the coating and cool the coated product, the inner surface of the tube being made of heat resistant non-sticking plastic material, the inner surface of the tube consisting of a material selected from the group consist-ing of polytetrafluoroethylene and polychlorotriuoroethylene.
4. Apparatus for lapplying and bonding a thin impervious metal coating to a continuous elongated metal wire of higher mel-ting point metal, comprising a chamber adapted to contain a bath of molten coating metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending a substantial distance downwardly from the bottom of the chamber, the inner diameter `of the tube being substantially uniform throughout the predominant pant of its length and equal to the outer diameter of the finished coated product, the upper end of the tube being open to the interior of the chamber and extending a substantial distance upwardly into the bath of molten metal but lying a substantial distance bel-ow `the top of the bath, the tube having a continuous inner surface made of heat resistance material to which the coating material does not stick during its passage therethrough, means to guide the wire in its travel down through the molten metal bath into the upper end of the tube, into the upper end of the tube, and through 4the tube, the tube having `a tirst zone of substantial length below and contiguous tothe `chamber which is exposed to the atmosphere, the tube having a second zone of substantial length below the `said irst, exposed zone, and means acting upon said second zone of the tube drastically to cool the tube to solidify the coating and cool the coated wire, and means below the lower end of the tube to pull the coated wire 4at substantially constant speed through the tube.
S. Apparatus for applying and bonding a thin impervious low melting point metal coating to a continuous elongated cylindrical metal wire `of higher melting point metal, comprising a chamber adapted to contain `a bath of molten coa-ting metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending a substantial distance downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform from substantially its upper to its lower end and equal to the outer diameter of the finished coated product, the upper end of the tube being open to the interior of the chamber and extending a substantial distance upwardly into the bath of molten metal but lying a substantial distance below the top of the bath, the tube having a continuous inner LlO surface made of heat-resistant plastic material to which the coating material does not stick during its passage therethrough, means to guide the wire in its travel down through the molten metal bath into the upper end of the tube, into the upper end of the tube, and through the tube, the tube having -a iirst zone of substantial length below and contiguous to the chamber which is exposed to the atmosphere for a substantial distance below the bottom of the chamber, a cooling jacket surrounding the tube at a second zone of substantial length ofthe tube below such exposed zone thereof, means to supply the jacket with cooling water and to cause such water to impinge upon the outer surface of the tube, whereby .to solidify the coating and cool the coated wire, and means below the lower end of the tube to pull the coated wire at substantially constant speed through .the tube.
6. Apparatus -ior applying and bonding a thin impervious metal coating to a continuous elongated metal wire of higher melting point metal, comprising a chamber adapted to contain a bath of molten `coating metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform throughout the predominant part of its length and equal to the outer diameter of the nished `coated product, the upper end of the tube being7 open to the interior of the chamber and extending a substantial distance upwardly into the bath of molten metal but lying a `substantial distance below the top of the bath, the tube having a continuous inner surface made of heat resistant plastic material to which the coating material does not stick during its passage therethrough, means to guide and continuously pull the wire at substantially constant speed down through the molten metal bath, into the upper end of the tube, and through the tube, the tube being exposed to the atmosphere for a substantial distance below the bottom of the chamber, and means below such exposed portion of the tube drastically to cool the tube to solidify the coating and cool the coated wire, the inner surface of the tube consisting of a material selected from the group consisting of polytetrauoroethylene and polychlorotritluoroethylene.
7. Apparatus for applying and bonding la thin impervious low melting point metal coa-ting to a continuous elongated cylindrical metal wire of higher melting point metal, comprising a chamber adapted to contain a bath of molten coating metal, means to maintain such bath at substantially constant elevated temperature, an elongated vertically disposed tube extending downwardly from the bottom of the chamber, the inner diameter of the tube being substantially uniform from substantially its upper to its lower end and equal to the outer diameter of the inished coated product, the upper end of the tube being open to the in-terior of the chamber and extending a substant-al distance upwardly into the bath of molten metal but lying a substantial distance below the top of the bath, the tube having a continuous inner surface made of heatresistant plastic material to which the coating material does not stick during its passage therethrough, means to guide and continuously pull the wire rat substantially constant speed down through the molten metal bath, into the upper end iot the tube, and through the tube, the tube being exposed to the atmosphere -for a substantial distance below the bottom of the chamber, a cooling jacket surrounding the tube below such exposed zone thereof, and means to supply the jacket with cooling water and to cause such water to impinge upon the outer surface of the tube, whereby to solidify the coating and drastically cool the coated wire, the inner surface of the tube consisting of a material selected from :the group consisting of polytetrauoroethylene Iand polychlorotriiluoroethylene.
(References on following page) 7 References Cited in the le of this patent 2,543,935 2,608,950 UNITED STATES PATENTS 2,842,329
1,370,800 Egerton Mar. S, 1921 2,386,818 seavey ocr. 16, 1945 5 519,669
5:5 Reynolds Mar. 6, 1951 Bradley Sept. 2, 1952 Brennan July l5, 1958 FOREIGN PATENTS Italy Mar. 15, 1955

Claims (1)

1. APPARTAUS FOR APPLYING AND BONDING A THIN IMPERVIOUS COATING TO A CONTINUOUS ELONGATED METAL CORE, COMPRISING A CHAMBER ADAPTED TO CONTAIN A BATH OF MOLTEN COATING MATERIAL, MEANS TO MAINTAIN THE BATH OF ELEVATED TEMPERATURE, AN ELONGATED GENERALLY VERTICALLY DISPOSED TUBE EXTENDING DOWNWARDLY FROM THE BOTTOM OF THE CHAMBER, THE INNER DIAMETER OF THE TUBE BEING SUBSTANTIALLY UNIFORM THROUGHOUT ITS LENGTH FROM SUBSTANTIALLY ITS UPPER TO ITS LOWER END AND EQUAL TO THE OUTER DIAMETER OF THE FINISHED COATED PRODUCT, THE UPPER END OF THE TUBE BEING OPEN TO THE INTERIOR OF THE CHAMBER BELOW THE TOP OF THE MOLTEN MATERIAL IN THE CHAMBER, THE TUBE EXTENDING A SUBSTANTIAL DISTANCE BELOW THE CHAMBER, MEANS CONTINUOUSLY TO PULL THE CORE DOWN THROUGH THE MOLTEN BATH OF COATING MATERIAL, INTO THE UPPER END OF THE TUBE, AND THROUGH THE TUBE, AND MEANS TO COOL THE TUBE AT A LOCATION BELOW THE CHAMBER WHEREBY TO SOLIDIFY THE COATING AND COOL THE COATED PRODUCTS, THE TUBE HAVING AN INNER SURFACE MADE OF HEAT RESISTANT PLASTIC MATERIAL TO WHICH THE COATING MATERIAL DOES NOT STICK DURING ITS PASSAGE THERETHROUGH, THE INNER SURFACE OF THE TUBE CONSISTING OF A MATERIAL SELECTED FROM THE GROUP CONSISTING OF POLYTETRAFLUOROETHYLENE AND POLYCHLOROTRIFLUOROETHYLENE.
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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3392700A (en) * 1964-08-07 1968-07-16 Loffland Brothers Combined spray and immersion coater for tubular stock
US3540918A (en) * 1967-03-17 1970-11-17 Siemens Ag Method of coating copper wire with solder
US3782326A (en) * 1971-03-16 1974-01-01 Australian Wire Ind Pty Primary water quench
US3853306A (en) * 1971-12-28 1974-12-10 Bethlehem Steel Corp Apparatus for quenching molten coatings
EP0032640A1 (en) * 1980-01-22 1981-07-29 New Zealand Wire Industries Limited Apparatus for wiping coated wire or strip
US5238517A (en) * 1987-10-15 1993-08-24 Cmb Foodcan Plc Production of laminated materials
US5368644A (en) * 1993-05-26 1994-11-29 Delgado; Cruz Mechanical solution applicating device and method for cleaning and/or lubricating raw stock material
US5644833A (en) * 1994-06-23 1997-07-08 D & L Incorporated Method of making dry, lubricated ejector pins
EP1457581A1 (en) * 2003-03-12 2004-09-15 CENTRE DE RECHERCHES METALLURGIQUES asbl - CENTRUM VOOR RESEARCH IN DE METALLURGIE vzw Controlling the thickness of a liquid surface coating layer on a long object emerging from a bath
EP2360286A1 (en) 2010-02-15 2011-08-24 Bogumil Miklasz The method of production a coated wire

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1370800A (en) * 1919-04-26 1921-03-08 Henry C Egerton Process of making extruded fibrous shapes
US2386818A (en) * 1942-12-12 1945-10-16 Olin Ind Inc Coating method and apparatus
US2543936A (en) * 1947-09-22 1951-03-06 Julian L Reynolds Apparatus for covering a metallic core with a cast layer of another metal
US2608950A (en) * 1950-06-09 1952-09-02 United Shoe Machinery Corp Thread waxing device
US2842820A (en) * 1955-01-12 1958-07-15 Joseph B Brennan Apparatus for casting metal

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1370800A (en) * 1919-04-26 1921-03-08 Henry C Egerton Process of making extruded fibrous shapes
US2386818A (en) * 1942-12-12 1945-10-16 Olin Ind Inc Coating method and apparatus
US2543936A (en) * 1947-09-22 1951-03-06 Julian L Reynolds Apparatus for covering a metallic core with a cast layer of another metal
US2608950A (en) * 1950-06-09 1952-09-02 United Shoe Machinery Corp Thread waxing device
US2842820A (en) * 1955-01-12 1958-07-15 Joseph B Brennan Apparatus for casting metal

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3392700A (en) * 1964-08-07 1968-07-16 Loffland Brothers Combined spray and immersion coater for tubular stock
US3540918A (en) * 1967-03-17 1970-11-17 Siemens Ag Method of coating copper wire with solder
US3782326A (en) * 1971-03-16 1974-01-01 Australian Wire Ind Pty Primary water quench
US3853306A (en) * 1971-12-28 1974-12-10 Bethlehem Steel Corp Apparatus for quenching molten coatings
EP0032640A1 (en) * 1980-01-22 1981-07-29 New Zealand Wire Industries Limited Apparatus for wiping coated wire or strip
US5238517A (en) * 1987-10-15 1993-08-24 Cmb Foodcan Plc Production of laminated materials
US5368644A (en) * 1993-05-26 1994-11-29 Delgado; Cruz Mechanical solution applicating device and method for cleaning and/or lubricating raw stock material
US5644833A (en) * 1994-06-23 1997-07-08 D & L Incorporated Method of making dry, lubricated ejector pins
EP1457581A1 (en) * 2003-03-12 2004-09-15 CENTRE DE RECHERCHES METALLURGIQUES asbl - CENTRUM VOOR RESEARCH IN DE METALLURGIE vzw Controlling the thickness of a liquid surface coating layer on a long object emerging from a bath
BE1015409A3 (en) * 2003-03-12 2005-03-01 Ct Rech Metallurgiques Asbl Checking the thickness of liquid layer on the surface of an object emerging stretch of bath.
EP2360286A1 (en) 2010-02-15 2011-08-24 Bogumil Miklasz The method of production a coated wire

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