Flat wire structure and apparatus and method of making same

Claim 2

A multi-wire structure comprising: a. a core member; and b. at least one strip of flat wire wrapped helically about the core member and having a preformed permanent helical twist about its longitudinal axis apart from the helical configuration assumed thereby when wrapped about the core member, said helical twist being in the direction of the helical wrap.

Claim 3

The wire structure according to claim 1 including: a. a plurality of the strips of flat wire wrapped helically in side-by-side relationship about the core member to form a single layer of the wire structure.

Claim 4

a support plate extending at an angle to the back plate, said angle brackets being held in back-to-back relationship for angular adjustment with respect to each other with the back plates of each extending in the same direction and the support plates of each extending in opposite directions; and

Claim 5

a support plate extending at an angle to the back plate, said angle brackets being held in back-to-back relationship for angular adjustment with respect to each other with the back plates of each extending in the same direction and the support plates of each extending in opposite directions; and

Claim 6

two strip holding and restraining means mounted on the frame at spaced intervals for directing the strip of flat wire longitudinally while at the same time holding spaced apart portions thereof against rotation with one of said portions held in a plane relative to the plane in which the other of said portions is held to maintain a twist in the wire disposed between the two portions, said strip holding and restraining means being mounted on said frame for angular adjustment with respect to each other; c. converging means for directing each pretwisted strip of flat wire along a path converging towards a predetermined point along the path of movement of the core member; and d. rotating means for rotating each pretwisted strip of flat wire about the core member as it is being advanced toward said point to helically wrap each strip of flat wire about the moving core member at said point.

Claim 7

two strip holding and restraining means mounted on the frame at spaced intervals for directing the strip of flat wire longitudinally while at the same time holding spaced apart portions thereof against rotation with one of said portions held in a plane relative to the plane in which the other of said portions is held to maintain a twist in the wire disposed between the two portions, said strip holding and restraining means being mounted on said frame for angular adjustment with respect to each other; c. converging means for directing each pretwisted strip of flat wire along a path converging towards a predetermined point along the path of movement of the core member; and d. rotating means for rotating each pretwisted strip of flat wire about the core member as it is being advanced toward said point to helically wrap each strip of flat wire about the moving core member at said point.

Claim 8

an opening extending through the back plates for permitting free passage of the strip of flat wire; and b. strip holding and restraining means mounted on the frame for directing the strip of flat wire longitudinally while at the same time holding spaced apart portions of the strip against rotation with one of said portions held in a plane relative to the plane in which the other of said portions is held to maintain a twist in a wire between the two portions, said strip holding and restraining means comprises two spaced apart pairs of strip holding rollers, each pair of rollers being mounted on one of said support plates with one pair of rollers being mounted for rotation about parallel axes disposed at an angle to the axes of rotation of the other pair of rollers, the rollers of each pair being positioned with respect to each other to define opposed strip holding surfaces engaging opposite sides of the strip of flat wire passing therebetween.

Claim 9

an opening extending through the back plates for permitting free passage of the strip of flat wire; and b. strip holding and restraining means mounted on the frame for directing the strip of flat wire longitudinally while at the same time holding spaced apart portions of the strip against rotation with one of said portions held in a plane relative to the plane in which the other of said portions is held to maintain a twist in a wire between the two portions, said strip holding and restraining means comprises two spaced apart pairs of strip holding rollers, each pair of rollers being mounted on one of said support plates with one pair of rollers being mounted for rotation about parallel axes disposed at an angle to the axes of rotation of the other pair of rollers, the rollers of each pair being positioned with respect to each other to define opposed strip holding surfaces engaging opposite sides of the strip of flat wire passing therebetween.

Claim 10

The wire structure according to claim 2 wherein: a. each strip of flat wire has a permanent deformation in the form of helical convolutions about the core member.

Claim 11

The wire structure according to claim 3 wherein: a. each strip of flat wire is made of a high yield strength material.

Claim 12

The wire structure according to claim 4 wherein: a. the strips of flat wire are radially compressed in place about the core member.

Claim 13

The wire structure according to claim 4 wherein: a. each strip of flat wire is made of copper having a reinforced core of high yield strength material.

Claim 14

The wire structure according to claim 6 further comprising: a. an outer strip of flat copper wire wrapped helically in spaced turns about the next underlying layer in a direction opposite thereto, said outer strip being compacted about the next underlying layer of the wire structure.

Claim 17

The method according to claim 8 wherein: a. a plurality of said helically twisted flat wires are wrapped about the core member to form a single layer of the wire structure.

Claim 18

The method according to claim 9 further comprising the step of: a. compacting each helically twisted wire tightly about the core member.

Claim 19

Apparatus for wrapping at least one strip of flat wire about a core member to produce a multi-wire structure comprising: a. means for moving the core member in one direction along a predetermined path; b. pretwisting and deforming means for imparting to each strip of flat wire a permanent helical pretwist in one direction about its longitudinal axis apart from the helical configuration of the flat wire about said core member, said pretwisting and deforming means comprising a plurality of stationary forming members each of which includes:

Claim 20

Apparatus for wrapping at least one strip of flat wire about a core member to produce a multi-wire structure comprising: a. means for moving the core member in one direction along a predetermined path; b. pretwisting and deforming means for imparting to each strip of flat wire a permanent helical pretwist in one direction about its longitudinal axis apart from the helical configuration of the flat wire about said core member, said pretwisting and deforming means comprising a plurality of stationary forming members each of which includes:

Claim 21

Apparatus as set forth in Claim 11 for wrapping a plurality of strips of flat wire about the core member to form a single layer of the wire structure wherein: a. said means for rotating each pretwisted strip of flat wire about the core member comprises a rotatable support disposed concentrically about the moving core member and through which the strips of flat wire pass at predetermined positions spaced thereabout in radially spaced relationship to the moving core member; b. said means for directing each pretwisted strip of flat wire along a path converging towards said predetermined point comprises a closing die located at said predetermined point through which the core member and flat wires pass as the latter are being helically wrapped about the moving core member.

Claim 22

Apparatus according to claim 12 wherein: a. said strip holding and restraining means comprises two spaced apart pairs of strip holding rollers, one pair of rollers being mounted for rotation about parallel axes disposed at an angle to the axes of rotation of the other pair of rollers.

Claim 23

Apparatus for deforming a strip of flat wire into a permanent helical twist about its longitudinal axis comprising: a. a frame having a pair of angular brackets each of which includes:

Claim 24

Apparatus for deforming a strip of flat wire into a permanent helical twist about its longitudinal axis comprising: a. a frame having a pair of angular brackets each of which includes:

Claim 25

Apparatus according to claim 14 wherein the strip holding surfaces of each pair of rollers are defined by mating tongue and groove surfaces extending around the periphery of the rollers of each pair.

Claim 26

Apparatus according to claim 15 wherein said groove has a width approximately equal to the width of the strip of flat wire.