Patent Publication Number: US-11027321-B2

Title: Device for scraping debris from metal wire

Description:
This application claims the benefit of U.S. patent application Ser. No. 14/807,089, (now U.S. Pat. No. 10,279,384), filed Jul. 23, 2015, the disclosure of which is incorporated herein by reference. 
     TECHNICAL FIELD 
     This document relates generally to wire cleaning devices, and more specifically to a multi segment device used to scrape debris from metal wire. 
     BACKGROUND 
     It is well known that the process of forming metal wire, commonly referred to as wire drawing, uses lubricants. Wire drawing is a metalworking process used to reduce a cross-section of a wire by pulling the wire through a single, or series of, drawing die(s). The process for drawing wire is relatively simple. First, the wire is prepared by shrinking a first end by hammering, filing, rolling or swaging, so that the wire will fit through the die. Second, the wire is pulled through the die. As the wire is pulled through the die, a volume of the wire remains the same. So, as the diameter of the wire decreases, the length of the wire increases. 
     Lubrication in the drawing process is essential for maintaining a good surface finish and extending the useful life of the die(s). Different methods of lubrication include, for example, wet drawing where the die(s) and wire are completely immersed in lubricant, dry drawing where the wire passes through a container of lubricant which coats the surface of the wire, and metal coating where the wire is coated with a soft metal which acts as a solid lubricant. The lubricants can include, for example, liquid lubricants such as an oil or copper (II) sulfate solution, or dry film lubricants among many others. Regardless of the type of lubricant utilized in the wire drawing process used to form the metal wire, lubricants can attract debris which adheres to the wire. Processes utilizing the metal wire which are sensitive to such debris can be negatively affected by the presence of the debris. One such process is the manufacturing of vehicles. 
     Accordingly, a need exists for a simple and inexpensive way to overcome issues related to the use of lubricants in the wire drawing process used to form metal wire. Ideally, the debris adhered to the metal wire due to the presence of the lubricant can be stripped from the metal wire. It would be desirable if a device could be utilized to strip the debris from the metal wire. Even more, it would be desirable if the metal wire being stripped did not require threading through the stripping device. 
     SUMMARY OF THE INVENTION 
     In accordance with the purposes and benefits described herein, a device for removing debris from a metal wire formed by a process utilizing a lubricant includes at least two segments forming a passage through which the metal wire passes, each of the at least two segments having a leading edge for stripping debris from the metal wire, and a resilient member positioned around the at least two segments and applying a force to the at least two segments sufficient to cause contact between the leading edges and the metal wire passing through the passage. 
     In one possible embodiment, the at least two segments form a substantially tubular passage. In another possible embodiment, the leading edge of each of the at least two segments substantially conforms to an outer diameter of the wire. 
     In still another possible embodiment, an inner surface of each of the at least two segments substantially conforms to an outer diameter of the wire. In yet another, the inner surface of each of the at least two segments is a wear resistant material attached to each of the at least two segments. 
     In another possible embodiment, the leading edge for stripping debris from the metal wire is in the shape of one of a small radius, a large radius, substantially no radius, a positive break, or a negative break. 
     In still another possible embodiment, the metal wire includes an outer protective coating and the force applied to the at least two segments is insufficient to scrape the outer protective coating from the wire. 
     In still yet another possible embodiment, the resilient member is one of a spring clamp, a snap ring, an O-ring, a spring, or an elastic band. In another, first and second ends of the resilient member are connected to create the force applied to the at least two segments. 
     In a second possible embodiment, a device for removing debris from a metal wire formed by a process utilizing a lubricant, includes at least two segments forming a passage through which the metal wire passes, each of the at least two segments having a leading edge for stripping debris from the metal wire, and first and second side edges, and a resilient member positioned around and applying a force to the at least two segments. In this embodiment, a first side edge of a first segment is connected to a second side edge of a second segment and a gap between a second edge of the first segment and a first edge of the second segment opens wide enough to allow the metal wire to pass therethrough for positioning of the metal wire within the passage. 
     In another possible embodiment, the force applied by the resilient member closes the gap after the metal wire is positioned within the passage and causes contact between at least the leading edges of the at least two segments and the metal wire passing through the passage. 
     In still another possible embodiment, the first side edge of the first segment and the second side edge of the second segment are hingedely connected. 
     In yet another possible embodiment, the leading edge of each of the at least two segments substantially conforms to an outer diameter of the wire. 
     In a third possible embodiment, a method of removing debris from a metal wire formed by a process utilizing a lubricant, includes the steps of: moving the metal wire through a passage formed by a plurality of segments; contacting the metal wire moving through the passage using a leading edge of each of the plurality of segments; and applying a force to the plurality of segments to cause contact between the leading edge of each of the plurality of segments and the metal wire passing through the passage. 
     In another possible embodiment, the method further includes the step of moving the metal wire through at least one straightener following the step of moving the metal wire through the passage formed by the plurality of segments. 
     In still another possible embodiment, the moving step includes pulling the metal wire from a roll of metal wire through the at least one straightener and the passage formed by the plurality of segments. 
     In yet another possible embodiment, the passage formed by the plurality of segments is fixed in position such that the metal wire moving through the passage is moving substantially horizontal. 
     In yet still another possible embodiment, the method further includes the step of collecting the debris removed from the metal wire in a container positioned beneath the leading edges of the plurality of segments. 
     In the following description, there are shown and described several embodiments of a device and related method for removing debris from a metal wire formed by a process utilizing a lubricant. As it should be realized, the devices and methods are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the methods and assemblies as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the device and method and together with the description serve to explain certain principles thereof. In the drawing figures: 
         FIG. 1  is a is a perspective view of a device for removing debris from a metal wire; 
         FIG. 2  is an end plan view of the device for removing debris from a metal wire; 
         FIG. 3  is a cross sectional view of a segment of an alternate embodiment of a device for removing debris from a metal wire showing a liner forming an inner surface of a passage formed by two segments of the device; 
         FIG. 4  is a perspective view of a device for stripping debris from a metal wire showing sides of segments of the device connected one to another except for a gap between two such sides which gap is utilized to position the metal wire within the device for stripping debris from the metal wire; and 
         FIG. 5  is an illustration of thermal spraying process within which the device for removing debris from a metal wire may be utilized. 
     
    
    
     Reference will now be made in detail to the present preferred embodiments of the device and related method for removing debris from a metal wire formed by a process utilizing a lubricant, examples of which are illustrated in the accompanying drawing figures, wherein like numerals are used to represent like elements. 
     DETAILED DESCRIPTION 
     Reference is now made to  FIGS. 1 and 2  which together illustrate a device  10  for removing debris from a metal wire (W) formed by a process utilizing a lubricant. The device  10  includes three segments  12  forming a substantially tubular passage  14  through which the metal wire (W) passes in the described embodiment. Each of the three segments  12  has a leading edge  16  for stripping debris from the metal wire. While the leading edges  16  of the segments  12  substantially conform to an outer diameter of the metal wire (W) as shown in  FIG. 2 , the noted passage  14  formed by the three segments  12  can take many shapes so long as the metal wire can pass through the device  10 . 
     In the described embodiment, an inner surface  18  of each of the three segments  12  substantially conforms to the outer diameter of the metal wire (W). In one alternate embodiment shown in  FIG. 3 , the inner surface  18  may be an inner surface of a wear resistant or plastic liner  19  attached to each of the three segments. Such wear resistant materials or plastics offer protection from surface marring and scratching, reduction in noise through contact with the passing metal wire, and offer oxidation and corrosion resistance. The leading edge  16  of each segment could form a portion of the segment  12  or the wear resistant liner. 
     As further shown in  FIG. 1 , the leading edges  16  are each small radiuses. In alternate embodiments, the leading edges could be larger radiuses, no, or substantially no, radiuses, or the leading edges could be angled forward or backward forming positive and negative breaks against the flow of the metal wire. 
     A resilient member  20  (e.g., an elastic band) is positioned around the three segments  12  and applies a force thereto. The force is sufficient to cause contact between the leading edges  16  and the metal wire (W) passing through the passage  14 . While contact between the leading edges  16  and the metal wire is desired, too much force resulting in scraping and/or deforming the metal wire is not. This is particularly true in instances where the metal wire includes an outer protective coating to prevent rust or provide some other function. In these instances, the force applied to the leading edges must be enough to strip debris from the metal wire but not enough to scrape the outer protective coating from the metal wire. 
     Although the resilient member  20  is described as an elastic band, the resilient member could be a spring or like device so long as the spring or like device is sufficient to apply the force. For example, the resilient member could be a spring, an O-ring, a snap ring, or a spring clamp, etc. Each type of resilient member  20  could slide over an end  22  of the device  10  or could wrap around the device. If wrapped around the device, the resilient member may include a connector (not shown) to connect first and second ends of the resilient member (e.g., snap ring ends) together, or the first and second ends could be tied together (e.g., elastic bands) or otherwise bound. Even more, the resilient member  20  could include one or more resilient members (e.g., two springs, or a snap ring and a spring, etc.) 
     In another alternate embodiment, the three segments  12  may be replaced with two or more segments similarly shaped to form the passage  16  through which the metal wire (W) passes. As indicated above, each segment includes a leading edge  14  for stripping debris, and shaped to conform to a portion of the outer diameter of the metal wire (W). The closer the leading edges come to approximating the outer diameter of the metal wire, the more efficient the leading edges will be at stripping debris. Even more, the smaller the gaps  24  between segments, the more efficient the stripping. 
     In the alternate embodiment shown in  FIG. 4 , each of the three segments have a leading edge  30  for stripping debris from a metal wire (W) and first and second side edges. A first side edge  32  of a first segment  34  is connected to a second side edge  36  of a second segment  38  and a gap  40  between a second edge  42  of the first segment  34  and a first edge  44  of a third segment  46  opens wide enough to allow the metal wire (W) to pass therethrough for positioning of the metal wire within a passage  48 . In this embodiment, the first side edge  32  of the first segment  36  and the second side edge  36  of the second segment  38  are hingedely connected. The same is true of the edges between the second segment  38  and the third segment  46 . Even more, the force applied by the resilient member (not shown) when wrapped around the device  28  closes the gap  40  after the metal wire (W) is secured in positioned within the passage  48  and causes contact between at least the leading edges  30  of the three segments  34 ,  38 , and  46  and the metal wire (W) passing through the passage  48 . 
     In other words, the segments forming the device are connected one to another except for a gap between edges of two of the segments, whether there are two segments or eight segments, in a clam shell type manner. In this manner, the gap between edges can be widened by temporarily overcoming the force of the resilient member (or positioning the wire within the passage of the device before positioning the resilient member) to allow the metal wire to pass therethrough for positioning of the metal wire within the passage. 
     The steps utilized in the method of the described embodiment are described with reference to  FIG. 5 . The process shown in  FIG. 5  to illustrate the method is a thermal spraying process although the described method may be used in any process requiring the use metal wire. Thermal spraying is a general phrase for a group of processes that utilize a heat source to melt material in powder, wire or rod form. In this instance, the material is a metal wire  60 . The molten or semi-molten material  62  is propelled by a spray gun  64 , attached to an air source  66  and a power source  68 , toward a prepared surface (S) by expanding process gases. The particles quench rapidly upon impact with the surface (S) and bond with the part (P). 
     In accordance with the method of removing debris from a metal wire formed by a process utilizing a lubricant, metal wire  60  is moved through a passage  70  of a device  72  formed by a plurality of segments  74 . As shown by action arrows A, the metal wire  60  is pulled from a spool  76  hung from a spool rack  78 . In alternate embodiments, the metal wire could be pulled from a barrel or a spool positioned on a floor or otherwise. 
     In a next step, a leading edge  80  of each of the plurality of segments  74  contacts the metal wire  60  moving through the passage  70  of the device  72 . A force is applied, in another step, to the plurality of segments  74  by a resilient member  76  to cause the contact between the leading edge of each of the plurality of segments and the metal wire. A container  82  is provided for collecting the debris removed from the metal wire  60 . 
     In the described embodiment, the container  82  is positioned beneath the leading edges  80  of the plurality of segments  74  where contact with the wire  60  occurs. In this arrangement, the metal wire  60  is pulled in a direction horizontal to the floor (F) allowing the debris to fall into the container (show by action arrow B) and not onto or into other element used in the process. Although not optimal, the wire may also be pulled in a vertical or angled direction as well. 
     Following the step of moving the metal wire through the passage formed by the plurality of segments, the wire  60  is moved, or pulled, through at least one wire straightener  84 . Positioning the wire straightener  84  downstream of the device  72  minimizes the buildup of debris from the metal wire  60  within the wire straightener  84  as the debris is generally removed by moving the wire through the passage. Of course, in alternate embodiments, the wire straightener could be positioned upstream of the passage. 
     In the described embodiment, the passage  70  formed by the plurality of segments  74  is fixed in position through abutment with the straightener  84 . As the metal wire  60  is pulled through the passage  70  and the straightener  84 , the device  72  is similarly pulled by friction created through contact between the metal wire  60  and the plurality of segments  74  toward the straightener. As the straightener  84  is fixed in a stationary position, the device  72  is likewise stationary. As described above, the metal wire  60  is pulled in a direction horizontal to the floor (F) in the described arrangement. 
     Upon exiting the straightener  84 , the wire  60  is pulled through a flexible tube  86  or conduit toward the spray head  64 . In the described embodiment, an electric drive  88  using pinch rollers within the spray head  64  is used to pull the metal wire  60  from the roll  76 , through the device  72  and wire straightener  84  and into the spray head. An external drive may be used, in an alternate embodiment, to pull the metal wire. For example, any pneumatic, hydraulic, or electric drive can be used to move or pull the metal wire. Within the spray head  64 , the metal wire  60  is melted and sprayed on a surface (S) of a part (P) as generally described above with regard to the thermal spraying process. The flexible tube  86  or conduit maintains the metal wire  60  in a debris free state after the device  72  has stripped debris from the metal wire. 
     In summary, numerous benefits result from the method of method of removing debris from a metal wire formed by a process utilizing a lubricant, are illustrated in this document. The method is capable of providing a simple and inexpensive way to overcome issues related to the use of lubricants in the wire drawing process used to form metal wire. In this instance, the debris adhered to the metal wire due to the presence of the lubricant can be stripped from the metal wire using a simple device. Even more, the stripping device is designed in one embodiment such that the metal wire being stripped is not required to be threading through the device. 
     The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.