Insulated magnet wire and method of forming the same

Abstract

Magnet wire is insulated with a paper insulation sheet which is longitudinally wrapped onto the wire. The paper sheet is precoated on one side with a layer of resinous adhesive dielectric material such as a thermoplastic polyester. The outside surface of the paper sheet has the resinous coating applied thereto and solidified prior to the time that the paper is wrapped onto the wire. Just prior to applying the paper to the wire, an edge of the resin coating is heated sufficiently to locally remelt the resin. The remelted edge is then overlapped by the opposite edge as the coated paper is wrapped onto the wire, whereby the edges of the insulation sheet are adhered together. The wrapped wire is then passed through one or more heated dies in order to remelt the entire resin coating, which remelted coating is then drawn back over the exterior of the paper layer. The wrapped wire is then passed through a water quench bath. The paper wrap is thus recoated in situ with the resin, thereby forming a continuous and uninterrupted resinous jacket on the paper and wire.

Dependencies are inferred from the claim text.