WO2009083994A2 - Glass-coated wires and methods for the production thereof - Google Patents

Glass-coated wires and methods for the production thereof Download PDF

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Publication number
WO2009083994A2
WO2009083994A2 PCT/IL2009/000016 IL2009000016W WO2009083994A2 WO 2009083994 A2 WO2009083994 A2 WO 2009083994A2 IL 2009000016 W IL2009000016 W IL 2009000016W WO 2009083994 A2 WO2009083994 A2 WO 2009083994A2
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WO
WIPO (PCT)
Prior art keywords
glass
core material
heat
heating device
wire
Prior art date
Application number
PCT/IL2009/000016
Other languages
French (fr)
Other versions
WO2009083994A3 (en
Inventor
Eliezer Adar
Yuri Bolotinsky
Original Assignee
D.T.N.R Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by D.T.N.R Ltd. filed Critical D.T.N.R Ltd.
Priority to JP2010541139A priority Critical patent/JP5562252B2/en
Priority to KR1020107017322A priority patent/KR101491547B1/en
Priority to CA2711431A priority patent/CA2711431C/en
Priority to EP09700129.1A priority patent/EP2238086B1/en
Priority to CN200980103993.2A priority patent/CN101970143B/en
Priority to ES09700129.1T priority patent/ES2575579T3/en
Priority to US12/811,415 priority patent/US8978415B2/en
Publication of WO2009083994A2 publication Critical patent/WO2009083994A2/en
Publication of WO2009083994A3 publication Critical patent/WO2009083994A3/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/02—Manufacture of glass fibres or filaments by drawing or extruding, e.g. direct drawing of molten glass from nozzles; Cooling fins therefor
    • C03B37/025—Manufacture of glass fibres or filaments by drawing or extruding, e.g. direct drawing of molten glass from nozzles; Cooling fins therefor from reheated softened tubes, rods, fibres or filaments, e.g. drawing fibres from preforms
    • C03B37/026—Drawing fibres reinforced with a metal wire or with other non-glass material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
    • B21C37/042—Manufacture of coated wire or bars

Definitions

  • the invention relates to production of glass-coated wires.
  • Glass-coated wires generally, although not necessarily, comprise a relatively small- diameter metal core (typically ranging in diameter from l ⁇ m up to any larger diameter) covered with a relatively thin glass coating a few ⁇ m in thickness.
  • These types of wires have found numerous applications in wire markets, including micro-wire markets, for example, in miniature electronic components; in security tags for personnel; in anti-theft tags for goods and merchandise; in anti-counterfeiting applications as well as in communication wires; and the like.
  • a method for glass coating of metal wires was first described by G. F. Taylor in 1924, and subsequently improved for relatively large-scale production by Ulitovsky in 1948.
  • the process is based on heating a glass tube containing a metal to a point where the metal melts and the glass, which has a substantially higher melting point than the metal, softens from the applied heat.
  • the glass is then drawn out to form a capillary tube with the molten metal forming a metal core inside the tube.
  • electromagnetic induction is used to heat the metal until melting, and the heat of the metal used to heat up the glass until it softens any may be drawn out.
  • An aspect of some embodiments of the invention relates to providing a method, apparatus, and a system for producing a glass-coated wire wherein a core material and a glass material used to form the glass-coated wire may be selected such that a melting temperature of the core material and a drawing temperature of the glass material (a temperature at which the glass may be stretched) are independent of each other.
  • glass-coated wires are generally fabricated using a glass tube containing a metal batch which is heated to a temperature sufficient to melt the metal by an electromagnetic field of an inductor.
  • the molten metal then softens the glass-tube walls.
  • the magnetic field of the inductor keeps the molten metal in the glass tube in a suspended state in a mid-portion of the inductor; so-called "method of suspended drop”.
  • a glass capillary is then drawn from the soft glass portion and wound on a rotating coil.
  • the glass-coated wire is formed from a "microbath" comprising the molten metal and the glass formed into a glass capillary filled with conductive metal core, allowing a continuous glass-coated wire to be formed.
  • the melting temperature of the metal is required to be controlled by varying a position of the metal within the inductor (under other equal conditions), while a wire diameter is controlled by varying the drawing speed.
  • Careful control of these variables is essential as a reduction in the speed of drawing results in an increase in wire diameter while an increase in drawing speed results in a decrease in wire diameter.
  • a 20 micron wire may require a drawing speed of approximately 800m/sec, while a 100 micron wire may require a drawing speed of approximately lOm/sec.
  • an apparatus for producing a glass-coated wire the apparatus adapted to separately melt the core material and soften the glass for drawing, enabling a core material with a substantially higher melting temperature than that of the glass to be used in the glass-coated wire.
  • the melting temperature of the core material may be the same or substantially lower compared to that of the glass.
  • the apparatus comprises a first heating device which is heated by a first electromagnetic inductor, the first device adapted to melt the core material; and further comprises a second device which is heated by a second electromagnetic inductor, the second device adapted to soften the glass for drawing.
  • the first device may be of heat- resistant steel, and is used for production of glass-coated wire from low temperature metals, for example, lead, copper, aluminum, and the like.
  • Such melting technology allows for a use of an inductor frequency range, from 0.5 kHz up to 30 kHz for the first inductor, for example, 2 - 10 kHz, providing relatively superior energy characteristics for the process.
  • a ceramic device may be used for preparation of glass-coated wire from high temperature metals.
  • the heating may be made within a frequency range of 30 - 800 kHz, for example, 66 - 500 kHz.
  • the molten core material flows out (as a stream or drops, depending on production requirements) from the first device into the second device.
  • the second device which may be made of heat-resistant steel, is further adapted to allow the molten core material to combine with the softened glass forming a glass-coated wire.
  • the glass-coated wire (glass capillary tube filled with the molten core) may then be drawn from the second device for cooling and subsequent processing as may be required for producing the glass-coated wire (for example, spooling).
  • a continuous feeding of core material into the first device and of glass material into the second device may allow for a continuous production of glass-coated wire.
  • the core material may be melted in the second device if the melting point of the core material is substantially close to that of the glass material.
  • the core material may be placed in the second device in a first region physically separated from the glass material which occupies a second region, and may be melted in the device by thermal conductivity from the heated glass.
  • the molten metal may then combine with the softened glass forming the glass-coated wire.
  • the glass-coated wire may then be drawn from the device for cooling and subsequent processing.
  • a system for producing a glass-coated microwire with an essentially circular cross-section which comprises the above-described apparatus, also comprises a cooling device for cooling the drawn glass-coated wire.
  • the cooling device which may include a tank with a cooling liquid, is adapted to provide the drawn glass-coated wire with a stable, non-turbulent cooling environment, rather than passing through an unstable and turbulent cooling stream as is common in the art.
  • uniformed cooling is applied to all sides of the glass-coated wire, and a uniform and undistorted glass coating may be achieved.
  • a uniform essentially circular cross-section is obtained for the glass-coated wire.
  • an apparatus for producing a glass-coated wire comprising at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof.
  • the apparatus further comprises an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
  • the apparatus further comprises at least one electromagnetic inductor adapted to heat the at least one heating device.
  • the at least one heating device comprises a heat-resistant metal.
  • the at least one heating device comprises a heat-resistant ceramic.
  • the core material is continuously fed to the at least one heating device.
  • the glass material is continuously fed to the at least one heating device.
  • the apparatus further comprises a first heating device adapted to heat the core material to a melting temperature thereof, and a second heating device adapted to heat the glass material to a drawing temperature thereof.
  • the apparatus further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device.
  • the molten core material flow is a stream.
  • the molten core material flow comprises falling drops.
  • the second device comprises a first region adapted to contain the molten core material.
  • the second device comprises a second region adapted to contain the heated glass material.
  • a method for producing a glass-coated wire comprising independently, heating a core material to a melting temperature thereof and heating a glass material to a drawing temperature thereof; and combining the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
  • the method further comprises independently heating by electromagnetic induction.
  • the method further comprises continuously feeding the core material.
  • the method further comprises continuously feeding the glass material
  • the method further comprises heating the core material in a first heating device, and heating the glass material in a second heating device.
  • the first device and/or the second device comprise a heat-resistant metal.
  • the first device and/or second device comprise a heat-resistant ceramic.
  • the method further comprises conducting molten core material flow from the first device to the second device.
  • the molten core material flow is a stream.
  • the molten core material flow comprises falling drops.
  • the method further comprises containing the molten core material in a first region in the second device. Additionally or alternative, the method further comprises containing the heated glass material in a second region in the second device.
  • a system for producing a glass-coated wire comprising an apparatus for producing a glass-coated wire, the apparatus comprising at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof; and a cooling device for cooling the glass-coated wire.
  • the cooling device comprises a tank filled with a liquid.
  • cooling device further comprises at least one pulley inside the tank around which the glass-coated wire passes.
  • the cooling device further comprises at least one pulley outside the tank around which the glass-coated wire passes.
  • the system further comprises an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
  • the system further comprises at least one electromagnetic inductor adapted to heat the at least one heating device.
  • the at least one heating device comprises a heat-resistant metal.
  • the at least one heating device comprises a heat-resistant ceramic.
  • the core material is continuously fed to the at least one heating device.
  • the glass material is continuously fed to the at least one heating device.
  • the system further comprises a first heating device adapted to heat the core material to a melting temperature thereof, and a second heating device adapted to heat the glass material to a drawing temperature thereof.
  • the system further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device.
  • the molten core material flow is a stream.
  • the molten core material flow comprises falling drops.
  • the second device comprises a first region adapted to contain the molten core material.
  • the second device comprises a second region adapted to contain the heated glass material.
  • the at least one heating device comprises a first region adapted to heat the core material to the melting temperature thereof, and a second region adapted to heat the glass material to the drawing temperature thereof.
  • the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof. Additionally or alternatively, the core material is shaped as a rod, a bar, or a wire.
  • the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof. Additionally or alternatively, the glass material comprises a form of a glass powder, a glass ball, or a glass tube.
  • a glass coated metal wire comprising an essentially circular cross-section.
  • an apparatus for producing a glass-coated wire comprising a first device adapted to be heated to a first temperature, the first temperature adapted to melt a core material; a second device adapted to be heated to a second temperature, the second temperature adapted to bring a glass material to a drawing temperature; and an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
  • the first temperature is greater than or equal to the second temperature.
  • the first temperature is less than the second temperature.
  • the apparatus further comprises a first electromagnetic inductor adapted to heat the first device.
  • the apparatus further comprises a second electromagnetic inductor adapted to heat the second device.
  • the core material is continuously fed to the first device.
  • the glass material is continuously fed to the second device.
  • the first device and/or the second device comprise a heat-resistant metal.
  • the first device and/or second device comprise a heat-resistant ceramic.
  • the apparatus further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device.
  • the molten core material flow is a stream.
  • the molten core material flow comprises falling drops.
  • the second device comprises a first region adapted to contain the molten core material.
  • the second device comprises a second region adapted to contain the heated glass material.
  • an apparatus for producing a glass-coated wire comprising a device comprising at least a first region and a second region, the first region is adapted to contain a core material and the second region is adapted to contain a glass material, wherein the device is adapted to be heated, to melt the core material and to bring a glass material to a drawing temperature; and an outlet adapted to combine the molten core material with the heated glass material to form a molten core material coated with glass.
  • the apparatus further comprises an electromagnetic inductor adapted to heat the device.
  • the core material is continuously fed to the first region.
  • the glass material is continuously fed to the second region.
  • the device comprises a heat-resistant metal.
  • the device comprises a heat-resistant ceramic.
  • a system for producing a glass-coated wire comprising an apparatus for producing a glass-coated wire, the apparatus comprising a first device adapted to be heated to a first temperature, the first temperature adapted to melt a core material; a second device adapted to be heated to a second temperature, the second temperature adapted to bring a glass material to a drawing temperature; an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass; and a cooling device for cooling the glass-coated wire.
  • the cooling device comprises a tank filled with a liquid.
  • the cooling device further comprises at least one pulley inside the tank around which the glass-coated wire passes. Additionally or alternatively, the cooling device further comprises at least one pulley outside the tank around which the glass-coated wire passes.
  • the first temperature is greater than or equal to the second temperature.
  • the first temperature is less than the second temperature.
  • the apparatus further comprises a first electromagnetic inductor adapted to heat the first device.
  • the apparatus further comprises a second electromagnetic inductor adapted to heat the second device.
  • the core material is continuously fed to the first device.
  • the glass material is continuously fed to the second device.
  • the first device and/or the second device comprise a heat-resistant metal.
  • the first device and/or second device comprise a heat-resistant ceramic.
  • the apparatus further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device.
  • the molten core material flow is a stream.
  • the molten core material flow comprises falling drops.
  • the second device comprises a first region adapted to contain the molten core material.
  • the second device comprises a second region adapted to contain the heated glass material.
  • a system for producing a glass-coated wire comprising an apparatus for producing a glass-coated wire, the apparatus comprising a device comprising at least a first region and a second region, the first region is adapted to contain a core material and the second region is adapted to contain a glass material, wherein the device is adapted to be heated, to melt the core material and to bring a glass material to a drawing temperature; an outlet adapted to combine the molten core material with the heated glass material to form a molten core material coated with glass; and a cooling device for cooling the glass-coated wire.
  • the apparatus further comprises an electromagnetic inductor adapted to heat the device.
  • the core material is continuously fed to the first region.
  • the glass material is continuously fed to the second region.
  • the device comprises a heat-resistant metal.
  • the device comprises a heat-resistant ceramic.
  • the glass material comprises a form of a glass powder, a glass ball, or a glass tube.
  • the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
  • the core material is shaped as a rod, a bar, or a wire.
  • the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
  • a method for producing a glass-coated wire comprising heating a first device containing a core material to a first temperature, thereby melting the core material; heating a second device containing a glass material to a second temperature, thereby bringing the glass material to a drawing temperature; and combining the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
  • the first temperature is greater than or equal to the second temperature.
  • the first temperature is less than the second temperature.
  • the method further comprises heating the first device with a first electromagnetic inductor.
  • the method further comprises heating the second device with a second electromagnetic inductor.
  • the method further comprises continuously feeding the core material is to the first device.
  • the method further comprises continuously feeding the glass material to the second device.
  • the first device and/or the second device comprise a heat- resistant metal.
  • the first device and/or second device comprise a heat-resistant ceramic.
  • the method further comprises conducting molten core material flow from the first device to the second device.
  • the molten core material flow is a stream.
  • the molten core material flow comprises falling drops.
  • the method further comprises containing the molten core material in a first region in the second device.
  • the method further comprises containing the heated glass material in a second region in the second device.
  • a method for producing a glass-coated wire comprising feeding a core material to a first region of a device; feeding a glass material to a second region of the device; heating the device thereby to melting the core material and bringing the glass material to a drawing temperature; and combining the molten core material with the heated glass material to form a molten core material coated with glass.
  • the method further comprises heating the device using electromagnetic induction.
  • the method further comprises continuously feeding the core material to the first region.
  • the method further comprises continuously feeding the glass material to the second region.
  • the device comprises a heat-resistant metal.
  • the device comprises a heat-resistant ceramic.
  • the method further comprises shaping the core material as a rod, a bar, or a wire.
  • the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
  • the method further comprises forming the glass material into a glass powder, a glass ball, or a glass tube.
  • the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
  • a glass-coated metal wire comprising an essentially circular cross-section.
  • Fig. 1 schematically illustrates an exemplary apparatus for producing a glass-coated wire, in accordance with an embodiment of the invention
  • FIG. 2 schematically illustrates an exemplary apparatus for producing a glass-coated wire, in accordance with another embodiment of the invention
  • Fig. 3 schematically illustrates an exemplary system for producing a glass-coated wire with an essentially circular cross-section, in accordance with an embodiment of the invention
  • Figure 4 schematically illustrates a flow chart illustrating a method for producing a glass-coated wire, in accordance with an embodiment of the invention.
  • FIG. 1 schematically illustrates an exemplary apparatus 10 for producing a glass-coated wire 19, in accordance with an embodiment of the invention.
  • Apparatus 10 is adapted to produce a glass-coated wire comprising a core material with a melting temperature and a glass material with a drawing temperature, which are independent from each other.
  • Apparatus 10 comprises a first device 14, which is heated by a first electromagnetic inductor 15, the first device adapted to melt a core material 13, which is fed into the device, for example, continuously.
  • Apparatus 10 further comprises a second device 17 which is heated by a second electromagnetic inductor 18, the second device adapted to melt
  • first device 14 and first inductor 15 may be included as part of a first induction heating furnace; and second device 17 and second inductor
  • continuous or continuous production may refer to, according to some embodiments, a process that produces a required length of wire (such as glass-coated wire) without a need to connect two or more segments of a wire to form the required length of wire.
  • continuous or continuous production may also refer to, according to some embodiments, a process that can produce a required length of a wire (such as glass coated wire) for as long as the core material and glass material are being fed into the system.
  • device which may also be referred to as “heating device” may refer to, according to some embodiments, any equipment or part of an equipment that can be heated and/or generate heat, for example, a crucible, furnace, oven, heating system, and the like.
  • Fist device 14 may be of heat-resistant steel, and may be used for production of glass- coated wire from low temperature metals, for example, lead, copper, aluminum, and the like. Such melting technology allows for a use of an inductor frequency range from 0.5 - 30 kHz, for example, from 2 kHz up to 10 kHz for first inductor 15, providing relatively superior energy characteristics for the process.
  • Core material 13 may comprise any shape adapted to be received by first device 14, for example, rod-shaped, wire-shaped, bar-shaped, and the like, and may be of a continuous length or optionally, limited length.
  • a diameter for a rod-shaped core material 13 may range from 0.1mm - 15mm, for example, from 0.1 mm - lmm, lmm - 2mm, 2mm - 6mm, 6mm - 8mm, 8mm - 12mm, 12mm - 15mm.
  • core material 13 may be any metal, metal alloy, elemental semiconductor, non-ceramic semiconducting compound, or metallic based superconductors, with melting temperatures greater than that of glass.
  • core material 13 may have a melting temperature equal to or lesser than glass.
  • metals may include copper, gold, silver, titanium, platinum, rhodium, iron, lead, nickel, alloys of these metals, and the like.
  • semiconductors may include Silicon (Si), Germanium (Ge), and the like.
  • non-ceramic semiconducting compounds may include Galium Antimonide (GaSb) and Indium Antimonide (InSb).
  • molten core material 16 produced in first device 14 by the melting of core material 13 flows out of the first device, through a conducting tube 101 (optionally thermally insulated) joining the first device with second device 17, into a first region comprising a cavity 162 in the second device.
  • Flow of molten core material 16 from first device 14 into second device 17 may be in the form of a continuous stream or continuous falling drops, depending on production requirements.
  • the flow may be intermittent (stops after a period of time).
  • Second device 17 which may be made of heat-resistant steel, is further adapted to allow molten core material 16 to combine with a softened glass 12 forming a glass-coated wire.
  • Glass material 11 which may be in the form of a glass powder, glass balls, glass tubes, and the like, may be fed, for example, continuously, into a second region comprising a funnel cavity
  • Glass material 11 may comprise, for example, quartz, silica, alkali silicate, soda-lime, borosilicate, aluminosilicate, lead, or any combination thereof.
  • Glass material 1 1 is melted into softened glass 12 by the heat generated in second device 17 by second inductor 18, the softened glass shaped as a funnel inside funnel cavity 160 with a small hole at an outlet 161.
  • Softened glass 12 then flows (or is drawn out) from second device 17 through outlet 161, the outlet adapted to combine molten core material 16 with softened glass 12 as it is stretched into a capillary tube at the outlet, forming glass-coated wire 19.
  • a size of outlet 161 is dependent on a required diameter of glass-coated wire 19, for example, as may be ordered by an end-user of the wire.
  • the size may be limited by a surface tension of softened glass 12 at a condition of viscosity which allows for control of the flow of the softened glass and/or molten metal 16.
  • a vacuum may be used to improve surface tension conditions, and may allow for a larger outlet size, for example, 5 mm diameter.
  • Apparatus 20 comprises a device 27 which is heated by an electromagnetic inductor 28, the device adapted to produce a glass-coated wire 29 from a core material 23 and a glass material 21 comprising a similar (close) melting temperature and drawing temperature, respectively.
  • Inductor 28 and device 27, comprising a cavity 262 (first region), funnel cavity 260 (second region), and an outlet 261, may be similar to second inductor 18 and second device 17 shown in Figure 1, including cavity 162, funnel cavity 160, and outlet 161, respectively.
  • Glass material 21 may be the same as that shown in Figure 1 at 11.
  • core material 23 which may be shaped similar to core material 13 in Figure 1 is placed in cavity 262 where it may be melted into molten core material 26 by thermal conductivity from the melting of glass material 21 into softened glass 22.
  • Softened glass 22 flows (or is drawn out) from device 27 through outlet 261, molten core material combining with softened glass 22 as it stretches into a capillary tube at the outlet, forming glass-coated wire 29.
  • System 30 comprises a glass-coated wire production apparatus 31 and a cooling device 35 for cooling a drawn capillary tube filled with the molten core material (glass-coated wire 32).
  • Cooling device 35 which may include a tank with a cooling liquid, is adapted to provide drawn glass-coated wire 32 with a stable, non-turbulent cooling environment, rather than passing through an unstable and turbulent cooling stream as is common in the art. As a result, uniformed cooling is applied to all sides of glass-coated wire 32, and a uniform and undistorted glass coating may be achieved.
  • a uniform essentially circular cross-section is obtained for glass-coated wire 32.
  • Apparatus 31 and glass-coated wire 32 may be the same or substantially similar to that shown in Figure 1 at 10 and 19, respectively.
  • apparatus 31 and glass-coated wire 32 may be the same or substantially similar to that shown in Figure 2 at 20 and 29.
  • System 30 further comprises at least one pulley 36 inside tank 35, and at least one pulley 33 outside of tank 35, the pulleys adapted to allow glass-coated wire 32 to be pulled through cooling tank 35 at a constant rate as it is being spooled, thereby maintaining a uniform cooling rate along a length of the glass-coated wire.
  • a liquid inlet line 34 adapted to allow a flow of cooling liquid into tank 35, as may be required to maintain appropriate cooling liquid temperature levels inside the tank.
  • the cooling liquid may include any liquid suitable for cooling glass-coated wire 32 and may include, for example, water, oil, alcohol, emulsions, and the like.
  • Fig. 4 schematically illustrates a flow chart illustrating an exemplary method for producing a glass-coated wire with apparatus 10 shown in Figure 1, in accordance with an embodiment of the invention.
  • the exemplary method described is not intended to be limiting in any form or manner, and a person skilled in the art may appreciate that variations are possible in the implementation of the method.
  • Step 41 In a first step of the method, the temperature of first device 14 must be heated to a melting temperature of core material 13.
  • First electromagnetic inductor 15 is energized so as to cause heating of the first device.
  • the temperature of second device 17 must be heated to a drawing temperature of glass material 1 1.
  • Second electromagnetic inductor 18 is energized so as to cause heating of the second device.
  • Step 42 In a second step of the method and following first device 14 and second device 17 reaching the required temperatures, respectively, core material 13 is fed into the first device and glass material 11 is fed into funnel cavity 160 in the second device. Feeding of the core material and the glass material may be continuous so as to achieve a continuous production of glass-coated wire 19. Optionally, feeding of the materials may be of a limited duration.
  • Step 43 In a third step of the method, core material 13 is melted in first device 14 into molten core material 16, and glass material 1 1 is melted in softened glass 12.
  • molten core material 16 flows into cavity 162 in second device 17.
  • the flow of molten core material may be in a stream from an outlet in first device 14 through a duct into the cavity.
  • the flow may be as drops.
  • the flow of the molten core may be continuous, or intermittent, varying according to production requirements.
  • Step 45 In fifth step of the method, softened glass 12 flows (or is drawn out) from device 17 through outlet 161, and combines with molten core material 16 flowing from cavity 162 as the softened glass is stretched into a capillary tube at the outlet.
  • Step 46 In a sixth step of the method, glass-coated wire 19 in the form of a glass capillary tube with molten core material inside is drawn out from second device 17 for cooling.
  • each of the words, "comprise” “include” and “have”, and forms thereof, are not necessarily limited to members in a list with which the words may be associated.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Surface Treatment Of Glass (AREA)
  • Glass Compositions (AREA)
  • Joining Of Glass To Other Materials (AREA)
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  • General Induction Heating (AREA)

Abstract

An apparatus for producing a glass-coated wire, the apparatus comprising at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof.

Description

GLASS-COATED WIRES AND METHODS FOR THE PRODUCTION THEREOF
CROSS-REFERENCE
This application claims priority of Israeli Patent application 188559 filed on January 3, 2008, the entire disclosure of which is incorporated herein by reference.
FIELD
The invention relates to production of glass-coated wires.
BACKGROUND
Glass-coated wires generally, although not necessarily, comprise a relatively small- diameter metal core (typically ranging in diameter from lμm up to any larger diameter) covered with a relatively thin glass coating a few μm in thickness. These types of wires have found numerous applications in wire markets, including micro-wire markets, for example, in miniature electronic components; in security tags for personnel; in anti-theft tags for goods and merchandise; in anti-counterfeiting applications as well as in communication wires; and the like.
A method for glass coating of metal wires was first described by G. F. Taylor in 1924, and subsequently improved for relatively large-scale production by Ulitovsky in 1948. Generally referred to as the Taylor-Ulitovsky Process, the process is based on heating a glass tube containing a metal to a point where the metal melts and the glass, which has a substantially higher melting point than the metal, softens from the applied heat. The glass is then drawn out to form a capillary tube with the molten metal forming a metal core inside the tube. Frequently, electromagnetic induction is used to heat the metal until melting, and the heat of the metal used to heat up the glass until it softens any may be drawn out.
SUMMARY
An aspect of some embodiments of the invention relates to providing a method, apparatus, and a system for producing a glass-coated wire wherein a core material and a glass material used to form the glass-coated wire may be selected such that a melting temperature of the core material and a drawing temperature of the glass material (a temperature at which the glass may be stretched) are independent of each other.
In the prior art, use of the Taylor-Ulitovsky method involves melting the core material inside a glass tube. Using heat created by electromagnetic induction, the core material, for example a metal (or a metal alloy) is melted and the heat of the metal softens (melts) the glass to a drawing temperature. This requires matching between the melting temperature of the metal and the glass drawing temperature. Consequently, the glass' technological viscosity necessary for glass-coated wire casting must be achieved at a temperature which is approximately equal to that of the metal melting temperature, inherently limiting a possibility of producing the glass-coated wire from high temperature metals (as it is difficult to choose glass types having drawing temperature which match the melting temperature of the high temperature metals). A similar problem exists with producing glass-coated wire from low temperature metals, for example with Pb (lead) or with Sn (tin) whose melting temperatures, Tm = 3270C and Tm = 2320C, respectively, are much lower compared to the drawing temperature of glass (1100 0C).
As previously discussed, based on the Taylor-Ulitovsky method, glass-coated wires are generally fabricated using a glass tube containing a metal batch which is heated to a temperature sufficient to melt the metal by an electromagnetic field of an inductor. The molten metal then softens the glass-tube walls. Usually, the magnetic field of the inductor keeps the molten metal in the glass tube in a suspended state in a mid-portion of the inductor; so-called "method of suspended drop". A glass capillary is then drawn from the soft glass portion and wound on a rotating coil. As a result the glass-coated wire is formed from a "microbath" comprising the molten metal and the glass formed into a glass capillary filled with conductive metal core, allowing a continuous glass-coated wire to be formed.
Although the Taylor-Ulitovsky process may seem an inherently simple technique, there are a number of interrelated variables over which careful control is required, and which may place limitations on mass production of glass-coated wire using the process. An important factor in achieving a stable process is an ability to maintain a constant size of micro-bath. For example, for a continuous process, continuous addition of metal is required using a metal feedstock which is fed into the melt at a pre-determined rate. Furthermore, as metal and glass are used up the glass requires continuous supply by a feeding tool in the area of the inductor.
At the same time, the melting temperature of the metal is required to be controlled by varying a position of the metal within the inductor (under other equal conditions), while a wire diameter is controlled by varying the drawing speed. Careful control of these variables is essential as a reduction in the speed of drawing results in an increase in wire diameter while an increase in drawing speed results in a decrease in wire diameter. For example, a 20 micron wire may require a drawing speed of approximately 800m/sec, while a 100 micron wire may require a drawing speed of approximately lOm/sec.
According to an aspect of some embodiments of the invention, there is provided an apparatus for producing a glass-coated wire, the apparatus adapted to separately melt the core material and soften the glass for drawing, enabling a core material with a substantially higher melting temperature than that of the glass to be used in the glass-coated wire. Optionally, the melting temperature of the core material may be the same or substantially lower compared to that of the glass.
In an embodiment of the invention, the apparatus comprises a first heating device which is heated by a first electromagnetic inductor, the first device adapted to melt the core material; and further comprises a second device which is heated by a second electromagnetic inductor, the second device adapted to soften the glass for drawing. The first device may be of heat- resistant steel, and is used for production of glass-coated wire from low temperature metals, for example, lead, copper, aluminum, and the like. Such melting technology allows for a use of an inductor frequency range, from 0.5 kHz up to 30 kHz for the first inductor, for example, 2 - 10 kHz, providing relatively superior energy characteristics for the process. For preparation of glass-coated wire from high temperature metals a ceramic device may be used. Use of the ceramic device may be necessary as the melting temperature of the high temperature metals, for example, platinum (Tm = 17690C), is higher than the operating temperature of the device made from heat-resistant steel. In this case the heating may be made within a frequency range of 30 - 800 kHz, for example, 66 - 500 kHz.
In some embodiments of the invention, the molten core material flows out (as a stream or drops, depending on production requirements) from the first device into the second device. The second device, which may be made of heat-resistant steel, is further adapted to allow the molten core material to combine with the softened glass forming a glass-coated wire. The glass-coated wire (glass capillary tube filled with the molten core) may then be drawn from the second device for cooling and subsequent processing as may be required for producing the glass-coated wire (for example, spooling). A continuous feeding of core material into the first device and of glass material into the second device may allow for a continuous production of glass-coated wire.
In some embodiments of the invention, the core material may be melted in the second device if the melting point of the core material is substantially close to that of the glass material. The core material may be placed in the second device in a first region physically separated from the glass material which occupies a second region, and may be melted in the device by thermal conductivity from the heated glass. The molten metal may then combine with the softened glass forming the glass-coated wire. The glass-coated wire may then be drawn from the device for cooling and subsequent processing.
According to an aspect of some embodiments of the invention, there is provided a system for producing a glass-coated microwire with an essentially circular cross-section. The system, which comprises the above-described apparatus, also comprises a cooling device for cooling the drawn glass-coated wire. The cooling device, which may include a tank with a cooling liquid, is adapted to provide the drawn glass-coated wire with a stable, non-turbulent cooling environment, rather than passing through an unstable and turbulent cooling stream as is common in the art. As a result, uniformed cooling is applied to all sides of the glass-coated wire, and a uniform and undistorted glass coating may be achieved. A uniform essentially circular cross-section is obtained for the glass-coated wire.
There is provided, in accordance with an embodiment of the invention, an apparatus for producing a glass-coated wire, the apparatus comprising at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof. Optionally, the apparatus further comprises an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass. In some embodiments of the invention, the apparatus further comprises at least one electromagnetic inductor adapted to heat the at least one heating device. Optionally, the at least one heating device comprises a heat-resistant metal. Additionally or alternatively, the at least one heating device comprises a heat-resistant ceramic. Optionally, the core material is continuously fed to the at least one heating device. Optionally, the glass material is continuously fed to the at least one heating device.
In some embodiments of the invention, the apparatus further comprises a first heating device adapted to heat the core material to a melting temperature thereof, and a second heating device adapted to heat the glass material to a drawing temperature thereof. Optionally, the apparatus further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device. Optionally, the molten core material flow is a stream. Additionally or alternatively, the molten core material flow comprises falling drops. Optionally, the second device comprises a first region adapted to contain the molten core material. Optionally, the second device comprises a second region adapted to contain the heated glass material.
There is provided, in accordance with an embodiment of the invention, a method for producing a glass-coated wire, the method comprising independently, heating a core material to a melting temperature thereof and heating a glass material to a drawing temperature thereof; and combining the molten core material with the heated glass material to form a wire comprising molten core material coated with glass. Optionally, the method further comprises independently heating by electromagnetic induction. Optionally, the method further comprises continuously feeding the core material. Optionally, the method further comprises continuously feeding the glass material
In some embodiments of the invention, the method further comprises heating the core material in a first heating device, and heating the glass material in a second heating device. Optionally, the first device and/or the second device comprise a heat-resistant metal. Optionally, the first device and/or second device comprise a heat-resistant ceramic. Additionally or alternative, the method further comprises conducting molten core material flow from the first device to the second device. Optionally, the molten core material flow is a stream. Optionally, the molten core material flow comprises falling drops. Optionally, the method further comprises containing the molten core material in a first region in the second device. Additionally or alternative, the method further comprises containing the heated glass material in a second region in the second device.
There is provided, in accordance with an embodiment of the invention, a system for producing a glass-coated wire the system comprising an apparatus for producing a glass-coated wire, the apparatus comprising at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof; and a cooling device for cooling the glass-coated wire. Optionally, the cooling device comprises a tank filled with a liquid. Optionally, cooling device further comprises at least one pulley inside the tank around which the glass-coated wire passes. Additionally or alternatively, the cooling device further comprises at least one pulley outside the tank around which the glass-coated wire passes.
In some embodiments of the invention, the system further comprises an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass. In some embodiments of the invention, the system further comprises at least one electromagnetic inductor adapted to heat the at least one heating device. Optionally, the at least one heating device comprises a heat-resistant metal.
Additionally or alternatively, the at least one heating device comprises a heat-resistant ceramic.
Optionally, the core material is continuously fed to the at least one heating device. Optionally, the glass material is continuously fed to the at least one heating device.
In some embodiments of the invention, the system further comprises a first heating device adapted to heat the core material to a melting temperature thereof, and a second heating device adapted to heat the glass material to a drawing temperature thereof. Optionally, the system further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device. Optionally, the molten core material flow is a stream. Additionally or alternatively, the molten core material flow comprises falling drops. Optionally, the second device comprises a first region adapted to contain the molten core material. Optionally, the second device comprises a second region adapted to contain the heated glass material.
In some embodiments of the invention, the at least one heating device comprises a first region adapted to heat the core material to the melting temperature thereof, and a second region adapted to heat the glass material to the drawing temperature thereof.
In some embodiments of the invention, the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof. Additionally or alternatively, the core material is shaped as a rod, a bar, or a wire. Optionally, the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof. Additionally or alternatively, the glass material comprises a form of a glass powder, a glass ball, or a glass tube.
There is provided, in accordance with an embodiment of the invention, a glass coated metal wire comprising an essentially circular cross-section. There is provided, in accordance with an embodiment of the invention, an apparatus for producing a glass-coated wire, the apparatus comprising a first device adapted to be heated to a first temperature, the first temperature adapted to melt a core material; a second device adapted to be heated to a second temperature, the second temperature adapted to bring a glass material to a drawing temperature; and an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass. Optionally, the first temperature is greater than or equal to the second temperature. Optionally, the first temperature is less than the second temperature. Optionally, the apparatus further comprises a first electromagnetic inductor adapted to heat the first device. Optionally, the apparatus further comprises a second electromagnetic inductor adapted to heat the second device. Additionally or alternatively, the core material is continuously fed to the first device. Optionally, the glass material is continuously fed to the second device. Optionally, the first device and/or the second device comprise a heat-resistant metal. Optionally, the first device and/or second device comprise a heat-resistant ceramic. Additionally or alternatively, the apparatus further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device. Optionally, the molten core material flow is a stream. Optionally, the molten core material flow comprises falling drops. Optionally, the second device comprises a first region adapted to contain the molten core material. Optionally, the second device comprises a second region adapted to contain the heated glass material.
There is provided, in accordance with an embodiment of the invention, an apparatus for producing a glass-coated wire, the apparatus comprising a device comprising at least a first region and a second region, the first region is adapted to contain a core material and the second region is adapted to contain a glass material, wherein the device is adapted to be heated, to melt the core material and to bring a glass material to a drawing temperature; and an outlet adapted to combine the molten core material with the heated glass material to form a molten core material coated with glass. Optionally, the apparatus further comprises an electromagnetic inductor adapted to heat the device. Optionally, the core material is continuously fed to the first region. Additionally or alternatively, the glass material is continuously fed to the second region. Optionally, the device comprises a heat-resistant metal. Optionally, the device comprises a heat-resistant ceramic.
There is provided, in accordance with an embodiment of the invention, a system for producing a glass-coated wire the system comprising an apparatus for producing a glass-coated wire, the apparatus comprising a first device adapted to be heated to a first temperature, the first temperature adapted to melt a core material; a second device adapted to be heated to a second temperature, the second temperature adapted to bring a glass material to a drawing temperature; an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass; and a cooling device for cooling the glass-coated wire. Optionally, the cooling device comprises a tank filled with a liquid. Optionally, the cooling device further comprises at least one pulley inside the tank around which the glass-coated wire passes. Additionally or alternatively, the cooling device further comprises at least one pulley outside the tank around which the glass-coated wire passes. Optionally, the first temperature is greater than or equal to the second temperature. Optionally, the first temperature is less than the second temperature. Optionally, the apparatus further comprises a first electromagnetic inductor adapted to heat the first device. Optionally, the apparatus further comprises a second electromagnetic inductor adapted to heat the second device. Additionally or alternatively, the core material is continuously fed to the first device. Optionally, the glass material is continuously fed to the second device. Optionally, the first device and/or the second device comprise a heat-resistant metal. Optionally, the first device and/or second device comprise a heat-resistant ceramic. Additionally or alternatively, the apparatus further comprises a conducting tube adapted to conduct molten core material flow from the first device to the second device. Optionally, the molten core material flow is a stream. Optionally, the molten core material flow comprises falling drops. Optionally, the second device comprises a first region adapted to contain the molten core material. Optionally, the second device comprises a second region adapted to contain the heated glass material.
There is provided, in accordance with an embodiment of the invention, a system for producing a glass-coated wire the system comprising an apparatus for producing a glass-coated wire, the apparatus comprising a device comprising at least a first region and a second region, the first region is adapted to contain a core material and the second region is adapted to contain a glass material, wherein the device is adapted to be heated, to melt the core material and to bring a glass material to a drawing temperature; an outlet adapted to combine the molten core material with the heated glass material to form a molten core material coated with glass; and a cooling device for cooling the glass-coated wire. Optionally, the apparatus further comprises an electromagnetic inductor adapted to heat the device. Optionally, the core material is continuously fed to the first region. Additionally or alternatively, the glass material is continuously fed to the second region. Optionally, the device comprises a heat-resistant metal. Optionally, the device comprises a heat-resistant ceramic.
In some embodiments of the invention, the glass material comprises a form of a glass powder, a glass ball, or a glass tube. Optionally, the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
In some embodiments of the invention, the core material is shaped as a rod, a bar, or a wire. Optionally, the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
There is provided, in accordance with an embodiment of the invention, a method for producing a glass-coated wire, the method comprising heating a first device containing a core material to a first temperature, thereby melting the core material; heating a second device containing a glass material to a second temperature, thereby bringing the glass material to a drawing temperature; and combining the molten core material with the heated glass material to form a wire comprising molten core material coated with glass. Optionally, the first temperature is greater than or equal to the second temperature. Optionally, the first temperature is less than the second temperature. Additionally or alternatively, the method further comprises heating the first device with a first electromagnetic inductor. Optionally, the method further comprises heating the second device with a second electromagnetic inductor. Optionally, the method further comprises continuously feeding the core material is to the first device. Optionally, the method further comprises continuously feeding the glass material to the second device. Additionally or alternatively, the first device and/or the second device comprise a heat- resistant metal. Optionally, the first device and/or second device comprise a heat-resistant ceramic. Optionally, the method further comprises conducting molten core material flow from the first device to the second device. Optionally, the molten core material flow is a stream. Optionally, the molten core material flow comprises falling drops. Optionally, the method further comprises containing the molten core material in a first region in the second device. Optionally, the method further comprises containing the heated glass material in a second region in the second device.
There is provided, in accordance with an embodiment of the invention, a method for producing a glass-coated wire, the method comprising feeding a core material to a first region of a device; feeding a glass material to a second region of the device; heating the device thereby to melting the core material and bringing the glass material to a drawing temperature; and combining the molten core material with the heated glass material to form a molten core material coated with glass. Optionally, the method further comprises heating the device using electromagnetic induction. Optionally, the method further comprises continuously feeding the core material to the first region. Additionally or alternatively, the method further comprises continuously feeding the glass material to the second region. Optionally, the device comprises a heat-resistant metal. Optionally, the device comprises a heat-resistant ceramic.
In some embodiments of the invention, the method further comprises shaping the core material as a rod, a bar, or a wire. Optionally, the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
In some embodiments of the invention, the method further comprises forming the glass material into a glass powder, a glass ball, or a glass tube. Optionally, the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
There is provided, in accordance with an embodiment of the invention, a glass-coated metal wire comprising an essentially circular cross-section.
BRIEF DESCRIPTION OF FIGURES
Examples illustrative of embodiments of the invention are described below with reference to figures attached hereto. In the figures, identical structures, elements or parts that appear in more than one figure are generally labeled with a same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily shown to scale. The figures are listed below.
Fig. 1 schematically illustrates an exemplary apparatus for producing a glass-coated wire, in accordance with an embodiment of the invention;
Fig. 2 schematically illustrates an exemplary apparatus for producing a glass-coated wire, in accordance with another embodiment of the invention; Fig. 3 schematically illustrates an exemplary system for producing a glass-coated wire with an essentially circular cross-section, in accordance with an embodiment of the invention; and
Figure 4 schematically illustrates a flow chart illustrating a method for producing a glass-coated wire, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
Reference is made to Fig. 1, which schematically illustrates an exemplary apparatus 10 for producing a glass-coated wire 19, in accordance with an embodiment of the invention.
Apparatus 10 is adapted to produce a glass-coated wire comprising a core material with a melting temperature and a glass material with a drawing temperature, which are independent from each other. Apparatus 10 comprises a first device 14, which is heated by a first electromagnetic inductor 15, the first device adapted to melt a core material 13, which is fed into the device, for example, continuously. Apparatus 10 further comprises a second device 17 which is heated by a second electromagnetic inductor 18, the second device adapted to melt
(soften) a glass material 11 fed into the device, for example, continuously, for drawing as a capillary tube. In accordance with an embodiment of the invention, continuous feeding of core material 13 into first device 14, and of glass material 1 1 into second device 17, allowing for a continuous production of glass-coated wire. First device 14 and first inductor 15 may be included as part of a first induction heating furnace; and second device 17 and second inductor
18, may be included as part of a second induction heating furnace.
The term "continuous" or "continuous production" may refer to, according to some embodiments, a process that produces a required length of wire (such as glass-coated wire) without a need to connect two or more segments of a wire to form the required length of wire. The term "continuous" or "continuous production" may also refer to, according to some embodiments, a process that can produce a required length of a wire (such as glass coated wire) for as long as the core material and glass material are being fed into the system. The term "device", which may also be referred to as "heating device", may refer to, according to some embodiments, any equipment or part of an equipment that can be heated and/or generate heat, for example, a crucible, furnace, oven, heating system, and the like.
Fist device 14 may be of heat-resistant steel, and may be used for production of glass- coated wire from low temperature metals, for example, lead, copper, aluminum, and the like. Such melting technology allows for a use of an inductor frequency range from 0.5 - 30 kHz, for example, from 2 kHz up to 10 kHz for first inductor 15, providing relatively superior energy characteristics for the process. For preparation of glass-coated wire from high temperature metals first device 15 may be a heat-resistant ceramic device. Use of the ceramic device may be necessary as the melting temperature of the high temperature metals, for example, platinum (Tm = 17690C), is higher than the operating temperature of the device made from heat-resistant steel. In this case the heating may be made within a frequency range of 30 - 800 kHz, for example, 66 - 500 kHz.
Core material 13 may comprise any shape adapted to be received by first device 14, for example, rod-shaped, wire-shaped, bar-shaped, and the like, and may be of a continuous length or optionally, limited length. A diameter for a rod-shaped core material 13 may range from 0.1mm - 15mm, for example, from 0.1 mm - lmm, lmm - 2mm, 2mm - 6mm, 6mm - 8mm, 8mm - 12mm, 12mm - 15mm. In accordance with an embodiment of the invention, core material 13 may be any metal, metal alloy, elemental semiconductor, non-ceramic semiconducting compound, or metallic based superconductors, with melting temperatures greater than that of glass. Optionally, core material 13 may have a melting temperature equal to or lesser than glass. Examples of metals may include copper, gold, silver, titanium, platinum, rhodium, iron, lead, nickel, alloys of these metals, and the like. Examples of semiconductors may include Silicon (Si), Germanium (Ge), and the like. Examples of non-ceramic semiconducting compounds may include Galium Antimonide (GaSb) and Indium Antimonide (InSb).
In accordance with some embodiments of the invention, molten core material 16 produced in first device 14 by the melting of core material 13, flows out of the first device, through a conducting tube 101 (optionally thermally insulated) joining the first device with second device 17, into a first region comprising a cavity 162 in the second device. Flow of molten core material 16 from first device 14 into second device 17 may be in the form of a continuous stream or continuous falling drops, depending on production requirements. Optionally, the flow may be intermittent (stops after a period of time).
Second device 17, which may be made of heat-resistant steel, is further adapted to allow molten core material 16 to combine with a softened glass 12 forming a glass-coated wire.
Glass material 11 , which may be in the form of a glass powder, glass balls, glass tubes, and the like, may be fed, for example, continuously, into a second region comprising a funnel cavity
160 in second device 17. Glass material 11 may comprise, for example, quartz, silica, alkali silicate, soda-lime, borosilicate, aluminosilicate, lead, or any combination thereof. Glass material 1 1 is melted into softened glass 12 by the heat generated in second device 17 by second inductor 18, the softened glass shaped as a funnel inside funnel cavity 160 with a small hole at an outlet 161.
Softened glass 12 then flows (or is drawn out) from second device 17 through outlet 161, the outlet adapted to combine molten core material 16 with softened glass 12 as it is stretched into a capillary tube at the outlet, forming glass-coated wire 19. A size of outlet 161 is dependent on a required diameter of glass-coated wire 19, for example, as may be ordered by an end-user of the wire. The size may be limited by a surface tension of softened glass 12 at a condition of viscosity which allows for control of the flow of the softened glass and/or molten metal 16. A vacuum may be used to improve surface tension conditions, and may allow for a larger outlet size, for example, 5 mm diameter.
Reference is made to Fig. 2, which schematically illustrates an exemplary apparatus 20 for producing a glass-coated wire 29, in accordance with another embodiment of the invention. Apparatus 20 comprises a device 27 which is heated by an electromagnetic inductor 28, the device adapted to produce a glass-coated wire 29 from a core material 23 and a glass material 21 comprising a similar (close) melting temperature and drawing temperature, respectively. Inductor 28 and device 27, comprising a cavity 262 (first region), funnel cavity 260 (second region), and an outlet 261, may be similar to second inductor 18 and second device 17 shown in Figure 1, including cavity 162, funnel cavity 160, and outlet 161, respectively. Glass material 21 may be the same as that shown in Figure 1 at 11.
In accordance with an embodiment of the invention, core material 23 which may be shaped similar to core material 13 in Figure 1 is placed in cavity 262 where it may be melted into molten core material 26 by thermal conductivity from the melting of glass material 21 into softened glass 22. Softened glass 22 flows (or is drawn out) from device 27 through outlet 261, molten core material combining with softened glass 22 as it stretches into a capillary tube at the outlet, forming glass-coated wire 29.
Reference is made to Fig. 3, which schematically illustrates an exemplary system 30 for producing a glass-coated wire 32 with an essentially circular cross-section, in accordance with an embodiment of the invention. System 30 comprises a glass-coated wire production apparatus 31 and a cooling device 35 for cooling a drawn capillary tube filled with the molten core material (glass-coated wire 32). Cooling device 35, which may include a tank with a cooling liquid, is adapted to provide drawn glass-coated wire 32 with a stable, non-turbulent cooling environment, rather than passing through an unstable and turbulent cooling stream as is common in the art. As a result, uniformed cooling is applied to all sides of glass-coated wire 32, and a uniform and undistorted glass coating may be achieved. A uniform essentially circular cross-section is obtained for glass-coated wire 32. Apparatus 31 and glass-coated wire 32 may be the same or substantially similar to that shown in Figure 1 at 10 and 19, respectively. Optionally, apparatus 31 and glass-coated wire 32 may be the same or substantially similar to that shown in Figure 2 at 20 and 29.
System 30 further comprises at least one pulley 36 inside tank 35, and at least one pulley 33 outside of tank 35, the pulleys adapted to allow glass-coated wire 32 to be pulled through cooling tank 35 at a constant rate as it is being spooled, thereby maintaining a uniform cooling rate along a length of the glass-coated wire. Additionally comprised is a liquid inlet line 34 adapted to allow a flow of cooling liquid into tank 35, as may be required to maintain appropriate cooling liquid temperature levels inside the tank. The cooling liquid may include any liquid suitable for cooling glass-coated wire 32 and may include, for example, water, oil, alcohol, emulsions, and the like.
Reference is made to Fig. 4, which schematically illustrates a flow chart illustrating an exemplary method for producing a glass-coated wire with apparatus 10 shown in Figure 1, in accordance with an embodiment of the invention. The exemplary method described is not intended to be limiting in any form or manner, and a person skilled in the art may appreciate that variations are possible in the implementation of the method. [Step 41] In a first step of the method, the temperature of first device 14 must be heated to a melting temperature of core material 13. First electromagnetic inductor 15 is energized so as to cause heating of the first device. Similarly, the temperature of second device 17 must be heated to a drawing temperature of glass material 1 1. Second electromagnetic inductor 18 is energized so as to cause heating of the second device.
[Step 42] In a second step of the method and following first device 14 and second device 17 reaching the required temperatures, respectively, core material 13 is fed into the first device and glass material 11 is fed into funnel cavity 160 in the second device. Feeding of the core material and the glass material may be continuous so as to achieve a continuous production of glass-coated wire 19. Optionally, feeding of the materials may be of a limited duration.
[Step 43] In a third step of the method, core material 13 is melted in first device 14 into molten core material 16, and glass material 1 1 is melted in softened glass 12.
[Step 44] In a fourth step of the method, molten core material 16 flows into cavity 162 in second device 17. The flow of molten core material may be in a stream from an outlet in first device 14 through a duct into the cavity. Optionally, the flow may be as drops. The flow of the molten core may be continuous, or intermittent, varying according to production requirements.
[Step 45] In fifth step of the method, softened glass 12 flows (or is drawn out) from device 17 through outlet 161, and combines with molten core material 16 flowing from cavity 162 as the softened glass is stretched into a capillary tube at the outlet.
[Step 46] In a sixth step of the method, glass-coated wire 19 in the form of a glass capillary tube with molten core material inside is drawn out from second device 17 for cooling. In the description and claims of embodiments of the present invention, each of the words, "comprise" "include" and "have", and forms thereof, are not necessarily limited to members in a list with which the words may be associated.
The invention has been described using various detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments may comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the invention that are described and embodiments of the invention comprising different combinations of features noted in the described embodiments will occur to persons with skill in the art.

Claims

CLAIMSWhat we claim is:
1. An apparatus for producing a glass-coated wire, the apparatus comprising:
at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof.
2. The apparatus of claim 1, further comprising an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
3. The apparatus of claim 1, further comprising a first heating device adapted to heat the core material to a melting temperature thereof, and a second heating device adapted to heat the glass material to a drawing temperature thereof.
4. The apparatus of claim 3 further comprising a conducting tube adapted to conduct molten core material flow from the first device to the second device.
5. The apparatus of claim 4 wherein the molten core material flow is a stream.
6. The apparatus of claim 4 wherein the molten core material flow comprises falling drops.
7. The apparatus of claim 3 wherein the second device comprises a first region adapted to contain the molten core material.
8. The apparatus of claim 3 wherein the second device comprises a second region adapted to contain the heated glass material.
9. The apparatus of claim 1, wherein the at least one heating device comprises a first region adapted to heat the core material to the melting temperature thereof, and a second region adapted to heat the glass material to the drawing temperature thereof.
10. The apparatus of claim 1 further comprising at least one electromagnetic inductor adapted to heat the at least one heating device.
1 1. The apparatus of claim 1 wherein the core material is continuously fed to the at least one heating device.
12. The apparatus of claim 1 wherein the glass material is continuously fed to the at least one heating device.
13. The apparatus of claim 1 wherein the at least one heating device comprises a heat- resistant metal.
14. The apparatus claim 1 wherein the at least one heating device comprises a heat-resistant ceramic.
15. The apparatus of claim 1 wherein the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
16. The apparatus of claim 1 wherein the core material is shaped as a rod, a bar, or a wire.
17. The apparatus of claim 1 wherein the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
18. The apparatus of claim 1 wherein the glass material comprises a form of a glass powder, a glass ball, or a glass tube.
19. A method for producing a glass-coated wire, the method comprising:
independently, heating a core material to a melting temperature thereof and heating a glass material to a drawing temperature thereof; and
combining the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
20. The method of claim 19 further comprising heating the core material in a first heating device, and heating the glass material in a second heating device.
21. The method of claim 20 wherein the first device and/or the second device comprises a heat-resistant metal.
22. The method of claim 20 wherein the first device and/or second device comprises a heat- resistant ceramic.
23. The method of claim 20 further conducting molten core material flow from the first device to the second device.
24. The method of claim 23 wherein the molten core material flow is a stream.
25. The method of claim 23 wherein the molten core material flow comprises falling drops.
26. The method of claim 20 further comprising containing the molten core material in a first region in the second device.
27. The method of claim 20 further comprising containing the heated glass material in a second region in the second device.
28. The method of claim 19 further comprising independently heating by electromagnetic induction.
29. The method of claim 19 further comprising continuously feeding the core material.
30. The method of claim 19 further comprising continuously feeding the glass material
31. The method of claim 19 wherein the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
32. The method of claim 19 further comprising shaping the core material as a rod, a bar, or a wire.
33. The method of claim 19 wherein the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
34. The method of claim 19 further comprising forming the glass material into a glass powder, a glass ball, or a glass tube.
35. A system for producing a glass-coated wire the system comprising:
an apparatus for producing a glass-coated wire, the apparatus comprising at least one heating device adapted to, independently, heat a core material to a melting temperature thereof and heat a glass material to a drawing temperature thereof; and
a cooling device for cooling the glass-coated wire.
36. The system of claim 35 wherein the cooling device comprises a tank filled with a liquid.
37. The system of claim 36 wherein the cooling device further comprises at least one pulley inside the tank around which the glass-coated wire passes.
38. The system of claim 36 wherein the cooling device further comprises at least one pulley outside the tank around which the glass-coated wire passes.
39. The system of claim 35 further comprising an outlet adapted to combine the molten core material with the heated glass material to form a wire comprising molten core material coated with glass.
40. The system of claim 35 further comprising a first heating device adapted to heat the core material to a melting temperature thereof, and a second heating device adapted to heat the glass material to a drawing temperature thereof.
41. The system of claim 40 further comprising a conducting tube adapted to conduct molten core material flow from the first device to the second device.
42. The system of claim 41 wherein the molten core material flow is a stream.
43. The system of claim 41 wherein the molten core material flow comprises falling drops.
44. The system of claim 40 wherein the second device comprises a first region adapted to contain the molten core material.
45. The system of claim 40 wherein the second device comprises a second region adapted to contain the heated glass material.
46. The system of claim 35 wherein the at least one heating device comprises a first region adapted to heat the core material to the melting temperature thereof, and a second region adapted to heat the glass material to the drawing temperature thereof.
47. The system of claim 35 further comprising at least one electromagnetic inductor adapted to heat the at least one heating device.
48. The system of claim 35 wherein the core material is continuously fed to the at least one heating device.
49. The system of claim 35 wherein the glass material is continuously fed to the at least one heating device.
50. The system of claim 35 wherein the at least one heating device comprises a heat- resistant metal.
51. The system of claim 35 wherein the at least one heating device comprises a heat- resistant ceramic.
52. The system of claim 35 wherein the core material comprises a metal, a metal alloy, an elemental semiconductor, a non-ceramic semiconducting compound, or ceramic powder, or any combination thereof.
53. The system of claim 35 wherein the core material is shaped as a rod, a bar, or a wire.
54. The system of claim 35 wherein the glass material comprises alkali silicate, borosilicate, aluminosilicate, quartz, silica, soda-lime, lead, or any combination thereof.
55. The system of claim 35 wherein the glass material comprises a form of a glass powder, a glass ball, or a glass tube.
56. A glass coated metal wire comprising an essentially circular cross-section.
PCT/IL2009/000016 2008-01-03 2009-01-04 Glass-coated wires and methods for the production thereof WO2009083994A2 (en)

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JP2010541139A JP5562252B2 (en) 2008-01-03 2009-01-04 Glass-coated wire manufacturing apparatus and manufacturing method
KR1020107017322A KR101491547B1 (en) 2008-01-03 2009-01-04 Glass-coated wires and methods for the production thereof
CA2711431A CA2711431C (en) 2008-01-03 2009-01-04 Glass-coated wires and methods for the production thereof
EP09700129.1A EP2238086B1 (en) 2008-01-03 2009-01-04 Glass-coated wires and methods for the production thereof
CN200980103993.2A CN101970143B (en) 2008-01-03 2009-01-04 Glass-coated wires and methods for the production thereof
ES09700129.1T ES2575579T3 (en) 2008-01-03 2009-01-04 Glass coated threads and their production procedures
US12/811,415 US8978415B2 (en) 2008-01-03 2009-01-04 Glass-coated wires and methods for the production thereof

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IL188559 2008-01-03
IL188559A IL188559A0 (en) 2008-01-03 2008-01-03 Method of production of glass coated metal wires and metal microwires

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CA2711431C (en) 2016-10-25
US20110036123A1 (en) 2011-02-17
EP2238086B1 (en) 2016-03-30
EP2238086A2 (en) 2010-10-13
WO2009083994A3 (en) 2010-01-07
KR101491547B1 (en) 2015-02-09
US8978415B2 (en) 2015-03-17
KR20100110352A (en) 2010-10-12
IL188559A0 (en) 2008-11-03
ES2575579T3 (en) 2016-06-29
JP2011511884A (en) 2011-04-14
CN101970143B (en) 2014-12-31
EP2238086A4 (en) 2013-08-28
CA2711431A1 (en) 2009-07-09
CN101970143A (en) 2011-02-09
JP5562252B2 (en) 2014-07-30

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