US3333999A - Method of making an insulated strip conductor - Google Patents

Method of making an insulated strip conductor Download PDF

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US3333999A
US3333999A US478952A US47895265A US3333999A US 3333999 A US3333999 A US 3333999A US 478952 A US478952 A US 478952A US 47895265 A US47895265 A US 47895265A US 3333999 A US3333999 A US 3333999A
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strip conductor
side edges
strip
dielectric film
edges
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US478952A
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Jr Ivan William Wade
Beebe Norman Percy
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ANAMAG Inc A CORP OF DE
Chase Commercial Corp
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Anaconda Wire and Cable Co
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/02—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding
    • H05K3/06—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding the conductive material being removed chemically or electrolytically, e.g. by photo-etch process
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/22—Secondary treatment of printed circuits
    • H05K3/28—Applying non-metallic protective coatings
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49155—Manufacturing circuit on or in base

Definitions

  • This invention relates to electrically insulated strip conductor for use in manufacturing electrical coils and the like. More particularly, it is directed to a method of manufacturing electrically insulated strip conductors and to the strip conductors per se which are fully insulated along their side edges by integral marginal edge portions of insulating films covering the broad faces of the strip.
  • insulating coatings which are applied to the copper strip be free from discontinuities which might cause short circuits in their electrical application.
  • the most common source of these discontinuities in the insulating coating has been found to occur along the side edges of the strip conductor. These side edges are the most common source of failings both because they are so difficult to coat properly with insulating varnishes or lacquers and also because they present such a relatively sharp edge that the insulating coatings either do not adhere properly or they become scraped off during handling, such as the winding operation required to form electrical coils.
  • a method often followed with aluminum strip conductors is to insulate them with an oxidic dielectric film.
  • the method almost universally followed is to cut narrow strip from a much wider strip.
  • this wide strip is cut longitudinally into narrower strips, the cutting operation always exposes the side edge of the narrower strip and leaves them rough with slivers and burrs.
  • the wider strips are coated with a dielectric insulating coating before the cutting operation, the flat surfaces may be adequately insulated, but the side edge portions must be covered over with a suitable insulation or they would surely be the source of a short circuit particularly in their use of electrical coils.
  • the electrically insulated strip conductor comprises a strip conductor with an electric insulating film on both flat surfaces of the strip conductor with the marginal side edges of the insulating film extending outwardly beyond the side edges of the strip conductor and folded back against the side edges of the strip conductor.
  • the respective edges of folded back marginal edge portions of the insulating film along each side edge of the strip conductor are adjoined and sealed to each other to insulate the side edges of the strip andfully insulate the strip conductor with said dielectric insulating fihn.
  • the method by which these strip conductors can most advantageously be made is first to coat the broad faces of a relatively wide metal strip with a dielectric film and then cut the strip into a plurality of relatively narrow strips which are each bare of any coating at their side edges.
  • the side edges of the strip conductor are then etched back between the dielectric film on the flat surfaces to form marginal edge portions of dielectric film 3,333,999 Patented Aug. 1, 1967 which project beyond the etched 'back side edges of the strip conductor.
  • the projecting marginal edges of the dielectric film are then folded against the side edges of the strip conductor and heat sealed together to insulate the side edges of the strip conductor and fully insulate the strip conductor with said dielectric film.
  • the strip conductor of the invention is fully insulated both at its broad faces and at its side edges by integral portions of dielectric film which are joined along the side edges. Because of the unitary and continuous coating of insulation from the broad faces around the sharp edges and against the side edges of the strip conductor, the problem of inadequate insulation at the edges is eliminated because the side edges are not insulated in a secondary operation by applying a separate dielectric insulation to the edges.
  • the insulation folded and sealed along the side edges was formerly applied as a uniform thickness coating to the broad faces of the strip, upon etching back, the side edges the marginal edge portions which extend beyond the side edges of the strip conductor are of the same uniform thickness as on the film on the broad faces of the strip conductor since these extended marginal edge portions formerly covered a broad face of the sheet.
  • a dielectric insulation of the same strength is provided along the side edges as well and a uniformly insulated strip conductor is realized.
  • FIG. 1 is a schematic of the steps in the method of forming the electrically insulated strip conductors
  • FIG. 2 is a fragmentary section of the strip conductor taken substantially along lines 2-2 of FIG. 1;
  • FIG. 3 is a fragmentary section of the strip taken substantially along lines 3-3 of FIG. 1;
  • FIG. 4 is a fragmentary section of a side edge of the strip during folding of the insulating film about the side edges taken substantially along the lines 4-4 of FIG. 1;
  • FIG. 5 is a fragmentary section of a side of the strip upon completion of the folding of the insulating film about the side edges taken substantially along the lines 55 of FIG. 1.
  • a coil 10 comprises a multiplicity of turns of flat metal strip, usually aluminum or copper of say .003 inch thickness.
  • the coil 10 is substantially wider than the desired magnet strip conductor width and is first fed to a coating station 11 where a liquid organic dielectric coating composition, for example a polyvinyl acetal, such as a polyvinylformal, or a silicone insulating enamel is applied to both broad faces of the wide flat metal strip.
  • a liquid organic dielectric coating composition for example a polyvinyl acetal, such as a polyvinylformal, or a silicone insulating enamel is applied to both broad faces of the wide flat metal strip.
  • This coating can be appliedby spray, roller, gravure, dip and the like, provided-a layer of such composition of uniform thickness is transferred to the broad faces of the advancing strip.
  • the coating composition Upon emerging from the coating apparatus, the coating composition is dried to a hardened condition.
  • the wide coated strip 12 is then directed through a slitting station 13 where a conventional continuous cutting apparatus is located for slitting the advancing wide strip longitudinally into a plurality of narrow strips.
  • a narrow width strip 14 is formed by slitting which has a uniform thickness dielectric film 15 and 16 on each broad face, but the side edges 17 of the strip are bare of insulation as the insulating films are coextensive with the side, edges of the strip.
  • the narrow strips exiting from the cutting apparatus are preferably then wound into a roll 18 while a thin plastic sheet is simultaneously fed with the strip conductor so that the roll is interleaved with this thin plastic sheet between successive turns.
  • Polyethylene sheets have been used with success for this operation.
  • the rolls can be interleaved with another sealant such as a heavy liq i like kerosene.
  • the roll 18 is then transferred to an etching station 19 where the side edges 17 are etched back to remove a portion of the strip conductor along the side edges and leave a void 20 between the insulating films and define new side edges 21 along the strip of reduced width as shown in FIG. 3.
  • Marginal edge portions 22 and 23 of the insulating film extend laterally out beyond the side edges 21 of the strip conductor on both sides, and the side edges are still free from insulation.
  • the etching bath can contain any of the conventional etching reagents such as a nitric acid or hydrochloric acid solution for aluminum or a ferric chloride solution for copper. Alternatively, the etching may be carried out in an electrolyte by making the roll the anode.
  • the plastic sheet or other sealant which is interleaved between the turns of the roll serves as a barrier to the etching solution penetrating between the turns of the roll where it might react with the insulating film and bond the turns together.
  • the etched strip is removed from the roll and. passed to a heat forming station 24 where heated forming rolls 25 are located on both sides of the strip being advanced therethrough.
  • the rolls are configured to receive the edges of the strip and progressively fold the extended integral marginal edge portions 22 and 23 of the dielectric insulating films 15 and 16 around the edges and down against the side edges 21 of the strip until the end edges 26 and 27 of adjacent marginal side edge portions meet and are heat sealed together longitudinally along the respective side edges thereof as shown in FIG. 5.
  • the strip conductor is fully insulated by a uniform thickness of dielectric insulation.
  • the side edges are insulated by integral marginal portions of the insulating films which insulate the broad faces of the strip conductor and the need to apply a secondary and separate side edge insulation is eliminated. It has been found that a strip conductor with the side edges coextensive with the insulation coating on the broad faces as shown in FIG. 2 has a dielectric strength which essentially measures zero. Once the side edge has been etched back as shown in FIG. 2 the dielectric strength varies from to 100 v. After folding and heat sealing the marginal edge portions of the insulating film as shown in FIG. 5, the dielectric strength increases to 200-500 v.
  • the strip When the strip is finally formed it is Wound into a roll of insulated strip conductor which is excellently suited for rewinding into a multilayer coil with the organic electric insulating film disposed within successive layers of the coil, and then suitable leads are attached,
  • a method of making an electrically insulated strip conductor comprising:
  • a method of making an electrically insulated strip conductor comprising:

Description

Au 1, 1 6 I. w. WADE, JR.. ETAL 3,333,999
METHOD OF MAKING AN INSULATED STRIP CONDUCTOR Filed Aug. 11. 1965 INVENTORS IV W. E, JR.
N AN EEBE 32 M 1 dflwg ATTORNEYS v United States Patent 3,333,999 METHOD OF MAKING AN INSULATED STRIP CONDUCTOR Ivan William Wade, Jr., Muskegon, and Norman Percy Beebe, Spring Lake, Micl1., assignors to Anaconda Wire and Cable Company, a corporation of Delaware Filed Aug. 11, 1965, Ser. No. 478,952 2 Claims. (Cl. 156-3) This invention relates to electrically insulated strip conductor for use in manufacturing electrical coils and the like. More particularly, it is directed to a method of manufacturing electrically insulated strip conductors and to the strip conductors per se which are fully insulated along their side edges by integral marginal edge portions of insulating films covering the broad faces of the strip.
In the manufacture of insulated magnet strip conductors such as are commonly used for the manufacture of electrical coils, it is essential that the insulating coatings which are applied to the copper strip be free from discontinuities which might cause short circuits in their electrical application. The most common source of these discontinuities in the insulating coating has been found to occur along the side edges of the strip conductor. These side edges are the most common source of failings both because they are so difficult to coat properly with insulating varnishes or lacquers and also because they present such a relatively sharp edge that the insulating coatings either do not adhere properly or they become scraped off during handling, such as the winding operation required to form electrical coils. A method often followed with aluminum strip conductors is to insulate them with an oxidic dielectric film.
In forming the narrow strips in the fabrication of the strip conductors, the method almost universally followed is to cut narrow strip from a much wider strip. When this wide strip is cut longitudinally into narrower strips, the cutting operation always exposes the side edge of the narrower strip and leaves them rough with slivers and burrs. Thus, even if the wider strips are coated with a dielectric insulating coating before the cutting operation, the flat surfaces may be adequately insulated, but the side edge portions must be covered over with a suitable insulation or they would surely be the source of a short circuit particularly in their use of electrical coils.
It is an object of this invention to provide an electrical strip conductor which is insulated along its side edges with integral marginal edge portions of the insulating films covering the broad faces of the strip, so that the strip conductor is completely insulated within these insulating films; the strip conductor is thereby insulated with an insulating film which is continuous throughout its length and is resistant to removal by abrasion during handling.
Broadly stated, the electrically insulated strip conductor comprises a strip conductor with an electric insulating film on both flat surfaces of the strip conductor with the marginal side edges of the insulating film extending outwardly beyond the side edges of the strip conductor and folded back against the side edges of the strip conductor. The respective edges of folded back marginal edge portions of the insulating film along each side edge of the strip conductor are adjoined and sealed to each other to insulate the side edges of the strip andfully insulate the strip conductor with said dielectric insulating fihn.
The method by which these strip conductors can most advantageously be made is first to coat the broad faces of a relatively wide metal strip with a dielectric film and then cut the strip into a plurality of relatively narrow strips which are each bare of any coating at their side edges. The side edges of the strip conductor are then etched back between the dielectric film on the flat surfaces to form marginal edge portions of dielectric film 3,333,999 Patented Aug. 1, 1967 which project beyond the etched 'back side edges of the strip conductor. The projecting marginal edges of the dielectric film are then folded against the side edges of the strip conductor and heat sealed together to insulate the side edges of the strip conductor and fully insulate the strip conductor with said dielectric film.
Unlike strip conductors heretofore made, the strip conductor of the invention is fully insulated both at its broad faces and at its side edges by integral portions of dielectric film which are joined along the side edges. Because of the unitary and continuous coating of insulation from the broad faces around the sharp edges and against the side edges of the strip conductor, the problem of inadequate insulation at the edges is eliminated because the side edges are not insulated in a secondary operation by applying a separate dielectric insulation to the edges. Moreover, because the insulation folded and sealed along the side edges was formerly applied as a uniform thickness coating to the broad faces of the strip, upon etching back, the side edges the marginal edge portions which extend beyond the side edges of the strip conductor are of the same uniform thickness as on the film on the broad faces of the strip conductor since these extended marginal edge portions formerly covered a broad face of the sheet. Thus, upon sealing along the side edges of the strip a dielectric insulation of the same strength is provided along the side edges as well and a uniformly insulated strip conductor is realized.
A preferred embodiment of the invention is described below with reference to the drawing wherein:
FIG. 1 is a schematic of the steps in the method of forming the electrically insulated strip conductors;
FIG. 2 is a fragmentary section of the strip conductor taken substantially along lines 2-2 of FIG. 1;
FIG. 3 is a fragmentary section of the strip taken substantially along lines 3-3 of FIG. 1;
FIG. 4 is a fragmentary section of a side edge of the strip during folding of the insulating film about the side edges taken substantially along the lines 4-4 of FIG. 1; and
FIG. 5 is a fragmentary section of a side of the strip upon completion of the folding of the insulating film about the side edges taken substantially along the lines 55 of FIG. 1.
As shown in FIG. 1, a coil 10 comprises a multiplicity of turns of flat metal strip, usually aluminum or copper of say .003 inch thickness. The coil 10 is substantially wider than the desired magnet strip conductor width and is first fed to a coating station 11 where a liquid organic dielectric coating composition, for example a polyvinyl acetal, such as a polyvinylformal, or a silicone insulating enamel is applied to both broad faces of the wide flat metal strip. This coating can be appliedby spray, roller, gravure, dip and the like, provided-a layer of such composition of uniform thickness is transferred to the broad faces of the advancing strip. Upon emerging from the coating apparatus, the coating composition is dried to a hardened condition.
The wide coated strip 12 is then directed through a slitting station 13 where a conventional continuous cutting apparatus is located for slitting the advancing wide strip longitudinally into a plurality of narrow strips. As shown in FIG. 2 a narrow width strip 14 is formed by slitting which has a uniform thickness dielectric film 15 and 16 on each broad face, but the side edges 17 of the strip are bare of insulation as the insulating films are coextensive with the side, edges of the strip.
The narrow strips exiting from the cutting apparatus are preferably then wound into a roll 18 while a thin plastic sheet is simultaneously fed with the strip conductor so that the roll is interleaved with this thin plastic sheet between successive turns. Polyethylene sheets have been used with success for this operation. Also the rolls can be interleaved with another sealant such as a heavy liq i like kerosene.
The roll 18 is then transferred to an etching station 19 where the side edges 17 are etched back to remove a portion of the strip conductor along the side edges and leave a void 20 between the insulating films and define new side edges 21 along the strip of reduced width as shown in FIG. 3. Marginal edge portions 22 and 23 of the insulating film extend laterally out beyond the side edges 21 of the strip conductor on both sides, and the side edges are still free from insulation. The etching bath can contain any of the conventional etching reagents such as a nitric acid or hydrochloric acid solution for aluminum or a ferric chloride solution for copper. Alternatively, the etching may be carried out in an electrolyte by making the roll the anode.
The plastic sheet or other sealant which is interleaved between the turns of the roll serves as a barrier to the etching solution penetrating between the turns of the roll where it might react with the insulating film and bond the turns together. Depending upon the insulating film used and method of etching selected, it may not be necessary to have any form of sealant between turns.
After etching, the etched strip is removed from the roll and. passed to a heat forming station 24 where heated forming rolls 25 are located on both sides of the strip being advanced therethrough. As shown in FIGS. 4 and 5, the rolls are configured to receive the edges of the strip and progressively fold the extended integral marginal edge portions 22 and 23 of the dielectric insulating films 15 and 16 around the edges and down against the side edges 21 of the strip until the end edges 26 and 27 of adjacent marginal side edge portions meet and are heat sealed together longitudinally along the respective side edges thereof as shown in FIG. 5. By this construction the strip conductor is fully insulated by a uniform thickness of dielectric insulation. The side edges are insulated by integral marginal portions of the insulating films which insulate the broad faces of the strip conductor and the need to apply a secondary and separate side edge insulation is eliminated. It has been found that a strip conductor with the side edges coextensive with the insulation coating on the broad faces as shown in FIG. 2 has a dielectric strength which essentially measures zero. Once the side edge has been etched back as shown in FIG. 2 the dielectric strength varies from to 100 v. After folding and heat sealing the marginal edge portions of the insulating film as shown in FIG. 5, the dielectric strength increases to 200-500 v.
When the strip is finally formed it is Wound into a roll of insulated strip conductor which is excellently suited for rewinding into a multilayer coil with the organic electric insulating film disposed within successive layers of the coil, and then suitable leads are attached,
We claim:
1. A method of making an electrically insulated strip conductor comprising:
(a) coating the broad faces of a relatively wide strip conductor with a dielectric film,
(b) cutting the strip conductor into a plurality of relatively narrow strip conductors which are each bare of any coating at their side edges,
(c) etching at least one of the side edges of the strip conductor back between the dielectric film on the flat surfaces to form integral marginal edge portions of dielectric film which project beyond the etched back side edges of the strip conductor,
((1) folding the projecting marginal edges of the dielectric film around the sharp edges of the conductor against the etched side edges of the strip conductor in adjoining contact with the adjacent marginal side edge portion on the opposite broad face of the strip conductor, and
(e) heat sealing the adjoining side edges together to fully insulate the edge of the strip conductor With said dielectric film.
2. A method of making an electrically insulated strip conductor comprising:
(a) coating the broad faces of a relatively wide strip conductor with a uniform thickness film of dielectric coating composition,
(b) cutting the wide strip conductor longitudinally into a plurality of relatively narrow strip conductors characterized by said films on each broad face being coextensive with the side edges of the narrow strip conductor, which side edges are each bare of any dielectric coating,
(c) winding the narrow strip conductor into a roll,
(d) etching the side edges of the strip conductor in roll form back between the layers of dielectric to define integral marginal edge portions of said dielectric films projecting beyond the etched back side edges of the strip conductor,
(e) unwinding the strip conductor from the roll,
(f) folding the integral marginal edge portions around the sharp edges of the strip conductor against the respective etched side edges of the strip conductor in adjoining contact with the edges of adjacent marginal side edge portion of layers on opposite faces of the strip conductor, and
(g) heat sealing the adjoining edges together longitudinally along the respective side edges of the strip conductor to fully insulate the strip conductor within the dielectric composition.
References Cited UNITED STATES PATENTS 2,393,486 1/1946 Storch. 2,728,036 12/1955 Steiner 317260 FOREIGN PATENTS 699,274 11/1953 Great Britain.
LEWIS H. MYERS, Primary Examiner.
E. GOLDBERG, Assistant Examiner.

Claims (1)

1. A METHOD OF MAKING AN ELECTRICALLY INSULATED STRIP CONDUCTOR COMPRISING: (A) COATING THE BROAD FACES OF A RELATIVELY WIDE STRIP CONDUCTOR WITH A DIELECTRIC FILM, (B) CUTTING THE STRIP CONDUCTOR INTO A PLURALITY OF RELATIVELY NARROW STRIP CONDUCTOR WHICH ARE EACH BARE OF ANY COATING AT THEIR SIDE EDGES, (C) ETCHING AT LEAST ONE OF THE SIDE EDGES OF THE STRIP CONDUCTOR BACK BETWEEN THE DIELECTRIC FILM ON THE FLAT SURFACES TO FORM INTEGRAL MARGINAL EDGE PORTIONS OF DIELECTRIC FILM WHICH PROJECT BEYOND THE ETCHED BACK SIDE EDGES OF THE STRIP CONDUCTOR, (D) FOLDING THE PROJECTING MARGINAL EDGES OF THE DIELECTRIC FILM AROUND THE SHARP EDGES OF THE CONDUCTOR AGAINST THE ETCHED SIDE EDGES OF THE STRIP CONDUCTOR IN ADJOINING CONTACT WITH THE ADJACENT MARGINAL SIDE EDGE PORTION ON THE OPPOSITE BROAD FACE OF THE STRIP CONDUCTOR, AND (E) HEAT SEALING THE ADJOINING SIDE EDGES TOGETHER TO FULLY INSULATE THE EDGE OF THE STRIP CONDUCTOR WITH SAID DIELECTRIC FILM.
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3525652A (en) * 1969-07-28 1970-08-25 Sumitomo Electric Industries Method of manufacturing an insulated foil conductor
JPS4985550A (en) * 1972-06-16 1974-08-16

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2393486A (en) * 1944-01-05 1946-01-22 Max H Storch Art of fabricating articles of decorative plastic elements
GB699274A (en) * 1951-08-07 1953-11-04 British Dielectric Res Ltd Improvements in or relating to electrical capacitors
US2728036A (en) * 1948-10-01 1955-12-20 Siemens Ag Electric condensers

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2393486A (en) * 1944-01-05 1946-01-22 Max H Storch Art of fabricating articles of decorative plastic elements
US2728036A (en) * 1948-10-01 1955-12-20 Siemens Ag Electric condensers
GB699274A (en) * 1951-08-07 1953-11-04 British Dielectric Res Ltd Improvements in or relating to electrical capacitors

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3525652A (en) * 1969-07-28 1970-08-25 Sumitomo Electric Industries Method of manufacturing an insulated foil conductor
JPS4985550A (en) * 1972-06-16 1974-08-16

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