Fused wires
AssigneeFort Wayne Metals Research Products Corporation
InventorsSean P. Telley, Christian W. Stacey
Life of this patent
Estimating the term…
Abstract
A method for fusing a pair of insulated wires to one another, and a fused wire made by such method, in which the combined or major diameter of the fused wire equals, or very closely matches, the sum of the diameters of the individual wires prior to fusion. In the present method, a pair of wires, each having a coating of insulation that is substantially fully cured, are brought into close abutting contact with one another along a line contact, and thereafter pass through a heating device which heats the coatings above their a thermal transition point of at least one of the pair of wires to fuse the coatings of the wires together along the line contact.
Claims21
A fused wire, comprising:
- a first wire including a first metal conductor surrounded by a first coating of cured fluoropolymer insulation, said first wire having a first diameter D1 between 0.002 and 0.015 inches;
- a second wire including a second metal conductor surrounded by a second coating of cured fluoropolymer insulation, said second wire having a second diameter D2 between 0.002 and 0.015 inches;
- and
- said first and second wires fused together along a line contact between said first and second coatings to form said fused wire, said fused wire having a major diameter D3, said fused wire further having a value Fusion % according to the following formula:
- Fusion %=[D3/(D1+D2)]×100% (I)
- wherein Fusion % is between 90% and 99.5% and
- wherein said first wire comprises a first cross-sectional size, said second wire comprises a second cross-sectional size, said first cross-sectional size different from said second cross-sectional size.
A fused wire, comprising:
- a wire including a first metal conductor surrounded by a first coating of cured fluoropolymer insulation, said wire having a first diameter D1 between 0.002 and 0.015 inches;
- a ribbon including a second metal conductor surrounded by a second coating of cured fluoropolymer insulation, said ribbon having a width D2 between 0.002 and 0.015 inches;
- and
- said wire and said ribbon fused together along a line contact between said first and second coatings to form said fused wire, said fused wire having a major diameter D3, said fused wire further having a value Fusion % according to the following formula:
- Fusion %=[D3/(D1+D2)]×100% (I)
- wherein Fusion % is between 90% and 99.5%.
A fused wire, comprising:
- a first wire including a first metal conductor surrounded by a first coating of cured fluoropolymer insulation, said first wire having a first diameter D1 between 0.002 and 0.015 inches;
- a second wire including a second metal conductor surrounded by a second coating of cured fluoropolymer insulation, said second wire having a second diameter D2 between 0.002 and 0.015 inches;
- and
- said first and second wires fused together along a line contact between said first and second coatings to form said fused wire, said fused wire having a major diameter D3, said fused wire further having a value Fusion % according to the following formula:
- Fusion %=[D3/(D1+D2)]×100% (I)
- wherein Fusion % is between 90% and 99.5% and
- wherein said first coating of insulation has a first thickness, said second coating of insulation has a second thickness, said first thickness different from said second thickness.
Dependencies are inferred from the claim text.