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US3877885A
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Copper-clad aluminum wire and method of making
Assignee: Texas Instruments Inc
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Filing: 1970-12-02
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Granted: 1975-04-15
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Expires: 1990-12-02
Abstract
Abstract A copper-clad aluminum wire is shown to have a cladding formed of electrolytic tough pitch copper. This copper material is selected in a particular way to assure that the copper material is free of particles of copper oxide exceeding a selected maximum size. Use of this cladding material provides a more economical copper-clad aluminum wire of improved electrical conductivity which is readily drawn by conventional wire drawing techniques without risk of damage to the wire cladding and without risk of wire breakage.
Inventors
- 👤 Peter Sexton
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 14:11
CPC Classifications
C; C22; C22F; C22F1/00; C22F1/08; B; B23; B23K; B23K20/00; B23K20/22; B23K20/233; B23K20/2333; B32; B32B; B32B15/00; B32B15/01; B32B15/017; H; H01; H01B; H01B1/00; H01B1/02; H01B1/023; H10; H10W; H10W72/00; H10W72/50; H10W72/521; H10W72/522; Y; Y10; Y10S; Y10S428/00; Y10S428/922; Y10S428/923; Y10S428/924; Y10S428/925; Y10T; Y10T428/00; Y10T428/12; Y10T428/12431; Y10T428/12438; Y10T428/12493; Y10T428/12736; Y10T428/1275
Claims Analysis
Total Claims: 11
Claim 1
Independent Claim
45 words
A COPPER-CLAD ALUMINUM WIRE COMPRISING AN ALUMINUM CORE HAVING A COPPER CLADDING METALURGICALLY BONDED TO SAID CORE, SAID CLADDING BEING FORMED OF ELECTROLYTIC TOUGH PITCH COPPER WHICH IS SUBSTANTIALLY FREE OF PARTICLES OF COPPER OXIDE HAVING A MAXIMUM TRANSVERSE DIMENSION GREATER THAN ABOUT 0.000190 INCHES.
Claim 2
Dependent Claim
45 words
A COPPER-CLAD ALUMINUM WIRE COMPRISING AN ALUMINUM CORE HAVING A COPPER CLADDING METALURGICALLY BONDED TO SAID CORE, SAID CLADDING BEING FORMED OF ELECTROLYTIC TOUGH PITCH COPPER WHICH IS SUBSTANTIALLY FREE OF PARTICLES OF COPPER OXIDE HAVING A MAXIMUM TRANSVERSE DIMENSION GREATER THAN ABOUT 0.000190 INCHES.
Claim 3
Dependent Claim
42 words
A copper-clad aluminum wire as set forth in claim 1 wherein said wire has a diameter in the range from 0.003 to 0.020 inches and wherein said copper-cladding material comprises up to about 15 percent of the total volume of said wire.
Claim 4
Dependent Claim
199 words
A copper-clad aluminum wire as set forth in claim 1 wherein said aluminum core is formed of a material selected from the group consisting of an alloy having a composition, by weight, of 99.45 percent (min.) aluminum and the balance impurities; an alloy having a composition, by weight, of 1.00 percent (max.) silicon plus iron, 0.20 percent (max.) copper, 0.05 percent (max.) manganese, 0.10 percent (max.) zinc, and the balance aluminum with no more than 0.05 percent of any other constituents and with no more than 0.15 percent total of other constituents; an alloy having a composition, by weight, of 0.45 percent (max.) silicon plus iron, 0.10 percent (max.) copper, 0.10 percent (max.) manganese, 2.2 to 2.8 percent magnesium, 0.15 to 0.35 percent chrOmium, 0.10 percent (max.) zinc, and the balance aluminum with no more than 0.05 percent of any other constituent and with no more than 0.15 percent total of other constituents; an alloy having a composition, by weight, of 0.7 percent iron, 0.15 percent magnesium 0.015 percent boron, 99.0 percent aluminum and the remainder impurities; and an alloy having a composition, by weight, of 0.85 percent iron, 0.015 percent boron, 99.0 percent aluminum and the remainder impurities.
Claim 5
Independent Claim
90 words
A method for making inexpensive composite, copper-clad aluminum wire of improved electrical conductivity which is adapted to be drawn to relatively small composite wire diameters on the order of 0.005 inches, said method comprising the steps of providing at least one strip of electrolytic tough pitch copper which is substantially free of particles of copper oxide therein having a maximum transverse dimension greater than about 0.000190 inches, providing an aluminum core wire, and metallurgically bonding said copper material to said aluminum core wire to form a composite copper-clad aluminum wire.
Claim 6
Independent Claim
90 words
A method for making inexpensive composite, copper-clad aluminum wire of improved electrical conductivity which is adapted to be drawn to relatively small composite wire diameters on the order of 0.005 inches, said method comprising the steps of providing at least one strip of electrolytic tough pitch copper which is substantially free of particles of copper oxide therein having a maximum transverse dimension greater than about 0.000190 inches, providing an aluminum core wire, and metallurgically bonding said copper material to said aluminum core wire to form a composite copper-clad aluminum wire.
Claim 7
Dependent Claim
28 words
A method as set forth in claim 4 wherein said copper material is metallurgically bonded to said aluminum core material in the solid phase of said copper material.
Claim 8
Dependent Claim
43 words
A method as set forth in claim 4 wherein said copper strip and aluminum core materials are of selected size such that said copper material in said composite wire comprises up to about 15 percent of the total volume of said composite wire.
Claim 9
Dependent Claim
198 words
A method as set forth in claim 4 wherein said aluminum core wire is formed of a material selected from the group consisting of an alloy having a composition, by weight, of 99.45 percent (min.) aluminum and the balance impurities; an alloy having a composition, by weight, of 1.00 percent (max.) silicon plus iron, 0.20 percent (max.) copper, 0.05 percent (max.) manganese, 0.10 percent (max.) zinc, and the balance aluminum with no more than 0.05 percent of any other constituents and with no more than 0.15 percent total of other constituents; an alloy having a composition, by weight, of 0.45 percent (max.) silicon plus iron, 0.10 percent (max.) copper, 0.10 percent (max.) manganese, 2.2 to 2.8 percent magnesium, 0.15 to 0.35 percent chromium, 0.10 percent (max.) zinc, and the balance aluminum with no more than 0.05 percent of any other constituent and with no more than 0.15 percent total of other constituents; an alloy having a composition, by weight, of 0.7 percent iron, 0.15 percent magnesium 0.015 percent boron, 99.0 percent aluminum and the remainder impurities; and an alloy having a composition, by weight, of 0.85 percent iron, 0.015 percent boron, 99.0 percent aluminum and the remainder impurities.
Claim 10
Independent Claim
125 words
A method for making inexpensive composite, copper-clad aluminum wire of improved electrical conductivity which is adapted to be drawn to relatively small composite wire diameters on the order of 0.005 inches, said method comprising the steps of casting cathode copper in relatively thin billets having a thickness up to about 5 inches and rapidly cooling said cast copper material to form a billet of electrolytic tough pitch copper which is substantially free of particles of copper oxide having a maximum transverse dimension greater than about 0.000190 inches, forming at least one strip of said copper material from said billet, providing an aluminum core wire, and solid phase metallurgically bonding said copper strip material to said aluminum core wire to form a composite copper-clad aluminum wire.
Claim 11
Independent Claim
125 words
A method for making inexpensive composite, copper-clad aluminum wire of improved electrical conductivity which is adapted to be drawn to relatively small composite wire diameters on the order of 0.005 inches, said method comprising the steps of casting cathode copper in relatively thin billets having a thickness up to about 5 inches and rapidly cooling said cast copper material to form a billet of electrolytic tough pitch copper which is substantially free of particles of copper oxide having a maximum transverse dimension greater than about 0.000190 inches, forming at least one strip of said copper material from said billet, providing an aluminum core wire, and solid phase metallurgically bonding said copper strip material to said aluminum core wire to form a composite copper-clad aluminum wire.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-04-14 | 1978-10-14 | 1979-04-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-04-14 | 1982-10-14 | 1983-04-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-04-14 | 1986-10-14 | 1987-04-15 | $7700.00 | Window Closed / Lapsed |