Abstract:
The invention is a method for forming a continuous strand of wire into a spiral support structure. The method includes winding a continuous strand of wire around a first central axis into a primary spiral. The primary spiral thereafter is stretched linearly to form an elongated spiral of desired pitch, which is then wound around a second central axis to form spiral support structure. This resulting spiral support structure can have two or more sides. The amount of sides depends on ratio of first axis to the second axis along with the pitch of the spiral. The crest and depressions of the structure are linearly aligned, and are parallel to each other.

Description:
BACKGROUND 
     Wire structures (e.g., concrete reinforcement bars, building components, etc.) are generally constructed from a plurality of wire coils. The wire coils are connected together (e.g., welded, wire tied, etc.) to form the wire structures. The wire structures constructed from a plurality of wire coils are generally unable to withstand various forces (e.g., vertical pressure, horizontal pressure, etc.) on the structure. Thus, there is a need in the art for an improved continuous wire coil and coiling method. 
     SUMMARY 
     One approach is a method that provides a continuous wire coil. The method includes winding a continuous strand of wire around a first rod to form a primary coil. The method further includes stretching the primary coil to form a primary spiral. The method further includes winding the stretched primary spiral around a second rod to form a secondary spiral. 
     Another approach is a continuous wire coil. The continuous wire coil includes a continuous wire wound in a double-spiral and a generally sinusoidal form aligned along a central axis. The continuous wire is connected together at one or more intersecting points formed by the sinusoidal form. 
     Another approach is an apparatus that provides for coiling a continuous wire coil. The apparatus includes a means for winding a continuous strand of wire around a first rod to form a primary coil. The apparatus further includes a means for stretching the primary coil to form a primary spiral. The apparatus further includes a means for winding the stretched primary spiral around a second rod to form a secondary spiral. 
     Any of the approaches described herein can include one or more of the following examples. 
     In some examples, the method further includes automatically and repeatedly winding the continuous strand of wire, stretching the primary coil, and winding the stretched primary spiral. 
     In other examples, the method further includes attaching one or more connected points of the secondary spiral together to form the continuous wire coil. 
     In some examples, the attaching the connected point further includes welding the one or more connected points. 
     In other examples, the first rod has a first diameter and the second rod has a second diameter. In some examples, the first diameter is a different size than the second diameter. 
     In other examples, the method further includes modifying the first diameter and/or the second diameter to modify a link space in the secondary spiral. 
     In some examples, the stretching the primary coil expands spacing of the continuous strand of wire. 
     In other examples, the method further includes applying pressure to the continuous strand of wire during winding the continuous strand of wire. 
     In some examples, the method further includes applying pressure to the stretched primary spiral during winding the stretched primary spiral. 
     In other examples, the winding the continuous strand of wire is in a first direction and the winding the stretched primary spiral is in a second direction. 
     In some examples, the first direction is different than the second direction. 
     In other examples, the continuous wire coil forms part of a building member, a tunnel structure, a bridge structure, a pole structure, and/or a pipeline structure. 
     In some examples, the continuous wire coil is a unitary piece of wire. 
     In other examples, the double-spiral forms link spacing between the one or more intersecting points. 
     In some examples, the continuous wire coil is formed from a spool of wire. 
     In other examples, the continuous wire is metal. 
     In some examples, the continuous wire coil includes a plurality of sides. The plurality of sides is formed by a size of each of the double-spirals. 
     In other examples, the apparatus further includes means for attaching one or more connected points of the secondary spiral together to form the continuous wire coil. 
     The wire coil technology described herein can provide one or more of the following advantages. An advantage of the technology is that the coiling method creates a synergistic effect over the unwound wire by dramatically increasing the strength of the coil with respect to the strength of the unwound wire. Another advantage of the technology is that the wire coil is easy to manufacture from a spool of wire, thereby decreasing the cost of manufacturing the wire coil. Another advantage of the technology is that the wire coil is easy to manufacture at any location, thereby increasing the available uses of the wire coil by decreasing transportation costs and increasing installation flexibility. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other objects, features and advantages will be apparent from the following more particular description of the embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. 
         FIG. 1  is a diagram of an exemplary wire coiling process; 
         FIGS. 2A-2F  are illustrations of exemplary wire coils; 
         FIG. 3  is a diagram of another exemplary wire coiling process; 
         FIGS. 4A-4B  are diagrams of exemplary pipes; 
         FIG. 5  is a diagram of an exemplary tunnel; and 
         FIG. 6  is a diagram of an exemplary building. 
     
    
    
     DETAILED DESCRIPTION 
     Wire coil technology, as described herein, can include a wire coil and a process of coiling the wire. The wire coil can be utilized in a stand-alone application (e.g., underground tunnel, culvert, etc.), integrated into other components (e.g., concrete reinforcement, coated in rubber for a pipeline, etc.), and/or attached to other components (e.g., inner reinforcement for a pipeline, internal building structure, etc.). The wire coil can be flexible and strong, thereby enabling the wire coil to be utilized in a variety of environments (e.g., pipeline in a earthquake prone environment, tunnel is a coastal environment, etc.). The flexibility of the wire coil enables the wire coil to flex in a changing environment (e.g., earthquake, wind, etc.) while still maintaining the strength to distribute loads (e.g., distribute earth about a tunnel, protect a pipeline from collapse, etc.). 
     In operation, the process of coiling the wire can include the following steps: 
     1. Wind a continuous strand of wire around a first rod with a first diameter (e.g., ten centimeter diameter, fifty centimeter diameter, etc.) to form a primary coil. The formation of the primary coil can form the initial winding of the wire into the wire coil that is utilized to size (e.g., horizontal size, vertical size, etc.) the wire coil. For example, a wire coil with a ten meter diameter is initially sized via the first winding step. 
     2. Stretch (e.g., stretch to double the original length, stretch to 1.5 the original length, etc.) the primary coil to expand the spacing of the wire to form a primary spiral. The stretching of the primary coil can be utilized to strengthen the wire coil (e.g., distributing the load horizontally, distributing the load vertically, etc.) by separating the wire during the formation of the primary spiral. 
     3. Wind the stretched primary spiral around a second rod with a second diameter (e.g., thirty centimeter diameter, two centimeter diameter, etc.) to create a secondary spiral (also referred to as a weave). The winding of the stretched primary spiral can form the double-spiral that is utilized to distribute loads through the wire coil while maintaining flexibility. 
     In some examples, the process further includes 4. Attaching (e.g., welding, bonding, etc.) the connected points of the secondary spiral together to form the wire coil. The attaching of the connected points can increase the strength of the wire coil (e.g., vertical compression strength, horizontal compression strength, etc.) by interconnecting the wire together to distribute any loads across the wire coil. 
     In other examples, the process of coiling the wire is a continuous method (steps 1, 2, 3, and/or 4 described above) and the steps can be completed sequentially with a continuous strand of wire. The continuous method decreases the cost of manufacturing by simplifying the process for manufacturing long wire coils. Although the continuous method is described as being utilized for long wire coils, the continuous method can be utilized for any length wire coil. 
     In some examples, the processing of coiling the wire is a non-continuous method (steps 1, 2, 3, and/or 4 described above). For example, in operation, step 1 is completed for a length of wire; then step 2 is completed for the length of wire; then step 3 is completed for the length of wire; and/or finally, step 4 is completed for the length of wire. The non-continuous method decreases the cost of manufacturing the wire coil by simplifying the process for manufacturing short wire coils. Although the non-continuous method is described as being utilized for short wire coils, the non-continuous method can be utilized for any length wire coil. 
     Generally, the wire coil is a continuous wire that is wound in a spiral along a longitudinal central axis of the wire coil. The wire coil is aligned along the central axis and connected together at intersecting points which increases the strength of the wire coil (e.g., horizontal strength, vertical strength, etc.) by distributing (e.g., load is distributed across the arches in the wire coil, load is distributed down the wires, etc.) any load across the length of the wire coil. The wire coil is a unitary piece that is turned along a longitudinal central axis, thereby decreasing the manufacturing cost and increasing the strength of the wire coil by evenly distributing loads through the wire coil. 
       FIG. 1  is a diagram of an exemplary wire coiling process  100 . The process  100  starts with a strand of wire  105  being feed (e.g., manually fed, automatically fed, etc.) to a winding device  110  with a first rod (e.g., five centimeter diameter, ten centimeter diameter, etc.). The winding device  110  can be a rotating drum, a drill with an attached rod, a lathe, and/or any type of device that can wind wire. The length of the first rod can be based on the size of the wire coil. For example, a wire coil  145  is ten meters long and the first rod is eight meters long to fit a primary coil  115 . In other examples, the length of the first rod is predetermined (e.g., one meter long, five hundred centimeters long, etc.). The winding device  110  winds the wire  105  around the first rod to form the primary coil  115 . The primary coil  115  is the initial winding of the wire  105  into a spiral. 
     The primary coil  115  is fed (e.g., manually fed, automatically fed, etc.) to a stretching device  120 . The stretching device  120  stretches the primary coil  115  to form a primary spiral  125 . The stretching device  120  can be a hydraulic ram, a pneumatic piston, and/or any type of device that can stretch wire. The primary coil  115  can be stretched a random length and/or a predetermined length (e.g., 150% of the length of the primary coil  115 , ten meters, etc.). The stretching of the primary coil  115  can advantageously increase the strength of the wire coil by separating out the wire, thereby increasing the load limits on the wire coil. 
     The primary spiral  125  is fed (e.g., manually fed, automatically fed, etc.) to a winding device  130  with a second rod (e.g., ten centimeter diameter, five centimeter diameter, etc.). The winding device  130  can be a rotating drum, a drill with an attached rod, a lathe, and/or any type of device that can wind wire. In some examples, the winding device  110  and the winding device  130  are the same type of winding device. In other examples, the winding device  110  and the winding device  130  are different types of winding devices. The winding device  130  winds the primary coil  125  around the second rod (e.g., different diameter from the first rod, same diameter as the first rod, etc.) to form a secondary spiral  135 . The secondary spiral  135  is the double-spiral and generally sinusoidal form of the wire coil. The double-spiral and generally sinusoidal form of the wire coil can advantageously distribute any loads along the wire coil (e.g., horizontal distribution, vertical distribution, etc.). 
     In some examples, the secondary spiral  135  is fed (e.g., manually fed, automatically fed, etc.) to an attachment device  140 . The attachment device  140  can be a welding device, a robot welding device, a cold welding device, an adhesive device, and/or any other type of device that can attach the wire. The attachment device  140  attaches one or more connected points on the secondary spiral  135  together to form a continuous wire coil  145  that provides additional strength along the longitudinal axis of the wire coil. The continuous wire coil  145  can be utilized for a variety of applications (e.g., tunnel, building support, pole, etc.). 
     In some examples, the first rod and the second rod have the same diameter (e.g., ten centimeters, thirty centimeters, etc.), thereby enabling the continuous wire coil  145  to be formed with a symmetrical aspect. In other examples, the first rod and the second rod have different diameters (e.g., the first rod has a ten centimeter diameter and the second rod has a twenty centimeter diameter, the first rod has a one centimeter diameter and the second rod has a three centimeter diameter, etc.), thereby enabling the continuous wire coil  145  to be formed with different numbers of sides (e.g., six sided continuous wire coil  145 , three sided continuous wire coil  145 , etc.). The sizes between the first rod and the second rod can be defined by a ratio and various ratios can be utilized to form different numbers of sides. For example, a ratio of 1:2 (first rod diameter to second rod diameter) is utilized to form four sides of the continuous wire coil  145 . The different number of sides advantageously enables the technology to be utilized for a variety of applications (e.g., a six sided continuous wire coil for a building application, a four sided continuous wire coil for a tunnel application, etc.). For example, a three sided continuous wire coil is more flexible than a six sided continuous wire coil. As another example, a six sided continuous wire coil is stronger than a three sided continuous wire coil. 
     In other examples, the winding device  110  and/or the winding device  130  applies pressure to the wire  105  and/or primary spiral  125 , respectively. The application of pressure enables the continuous wire coil  145  to be formed with different number of sides. In some examples, the ratio between the diameters of the first rod and the second rod and the application of pressure is utilized to form different number of sides for the continuous wire coil  145 . In other examples, the ratio between the diameters of the first rod and the second rod and the application of pressure is utilized to form various link spacing in the continuous wire coil  145 . The link spacing is the size of the opening in the continuous wire coil  145  between the wire and/or intersecting points. For example, the link spacing has an area of ten square centimeters. As another example, the link spacing has an area of twenty square centimeters. The link spacing can enable the formation of different size and/or strength continuous wire coils. The link spacing can advantageously increase the flexibility of the wire coil  200   a  while substantially maintaining the strength (e.g., 99% of the strength, 96% of the strength, etc.) of a similar wire coil without such link spacing. For example, a smaller link spacing (e.g., under one square centimeter, under ten square centimeters, etc.) is utilized to increase the strength of the continuous wire coil  145 . In another example, a medium link spacing (e.g., between three and four square centimeters, between four and six square centimeters, etc.) is utilized to balance the strength of the continuous wire coil  145  and the use of wire in the continuous wire coil  145 . 
       FIG. 2A  is an illustration of an exemplary wire coil  200   a . The wire coil  200   a  includes a continuous wire that is would in a double-spiral aligned along a longitudinal central axis  210   a . The wire coil  200   a  is generally in a sinusoidal form  220   a . For example, the wire coil  200   a  is formed as a 98% sinusoidal form. As another example, the wire coil  200   a  is formed as a 95% sinusoidal form. The sinusoidal form  220   a  form as arch for the wire coil  200   a  between intersecting points  230   a . The arch for the wire coil  200   a  advantageously increases the strength of the wire coil  200   a  by distributing the weight of a load across the length of the wire coil  200   a  (e.g., distributed through ten of the intersecting points, distributed across four inches of the wire coil  200   a , etc.). The intersecting points  230   a  for link spacing  240   a  in the wire coil  200   a . As described herein, the link spacing  240   a  can be sized based on a variety of parameters (e.g., strength, weight, cost, etc.). 
       FIG. 2B  is an illustration of another exemplary wire coil  200   b . The wire coil  200   b  has five sides  250   a . As described herein, the number of sides of the wire coil  200   b  can be formed based on the pressure applied during the winding processes and/or the ratio between the first rod and the second rod. The number of sides can be set based on the application (e.g., building member, bridge structure, tunnel structure, pipeline structure, pole structure, etc.) of the wire coil  200   b.    
       FIG. 2C  is an illustration of another exemplary wire coil  200   c . The wire coil  200   c  is wound in a double-spiral  222   c  aligned along a central axis  210   c  which forms a plurality of arches between intersecting points  230   c . The intersecting points  230   c  form link spacing  240   c  between the intersecting points  230   c.    
       FIG. 2D  is an illustration of another exemplary wire coil  200   d . The wire coil  200   d  has four sides  250   d.    
       FIG. 2E  is an illustration of another exemplary wire coil  200   e . The wire coil  200   e  has five sides  250   e.    
       FIG. 2F  is an illustration of another exemplary wire coil  200   f . The wire coil  200   f  has seven sides  250   f . The wire coil  200   f  can be any size (e.g., ten meters in length by one meter wide, twelve meters in length by two meters wide, etc.) and/or can be constructed from any type of material (e.g., plastic, metal, composite, etc.). 
       FIG. 3  is a diagram of another exemplary wire coiling process  300  utilizing, for example, a coiling apparatus. The coiling apparatus winds ( 310 ) a continuous strand of wire around a first rod to form a primary coil. The coiling apparatus stretches ( 320 ) the primary coil to form a primary spiral. The coiling apparatus winds ( 330 ) the stretched primary spiral around a second rod to form a secondary spiral. 
     In some examples, the coiling apparatus automatically and repeatedly ( 340 ) winds ( 310 ) the continuous strand of wire, stretches ( 320 ) the primary coil, and winds ( 330 ) the stretched primary spiral. The automatic and repeating ( 340 ) of part of the process advantageously enables the coiling apparatus to quickly and efficiently manufacture wire coils. 
     In other examples, the coiling apparatus attaches ( 350 ) one or more connected points of the secondary spiral together to form the continuous wire coil. In some examples, the attaching ( 350 ) the connected point further includes welding the one or more connected points. 
     In some examples, the first rod has a first diameter and the second rod has a second diameter. In other examples, the first diameter is a different size than the second diameter. 
     In some examples, the coiling apparatus modifies ( 315 ) the first diameter and/or modifies ( 335 ) the second diameter to modify a link space in the secondary spiral. In other examples, the stretching ( 320 ) the primary coil expands spacing of the continuous strand of wire. 
     In some examples, the coiling apparatus applies pressure (e.g., application of pad on wire, tightening of fed mechanism, etc.) to the continuous strand of wire during winding the continuous strand of wire. In other examples, the coiling apparatus applies pressure (e.g., application of pad on wire, tightening of fed mechanism, etc.) to the stretched primary spiral during winding the stretched primary spiral. 
     In some examples, the winding ( 310 ) the continuous strand of wire is in a first direction (e.g., clockwise, counter-clockwise) and winding ( 320 ) the stretched primary spiral is in a second direction (e.g., clockwise, counter-clockwise, etc.). In other examples, the first direction is different than the second direction. 
       FIG. 4A  is diagram of an exemplary pipe  400   a . The pipe  400   a  includes an inner wire coil  220   a  and an outer plastic tube  230   a . The plastic tube  230   a  can be placed over the wire coil  220   a . In other examples, the plastic tube  230   a  is sprayed on the wire coil  220   a . The pipe  400   a  can be utilized for fluid delivery (e.g., water, gas, oil, etc.). 
       FIG. 4B  is diagram of an exemplary pipe  400   b . The pipe  400   b  includes an inner plastic tube  230   b  and an outer wire coil  220   b . The plastic tube  230   b  can be placed within the wire coil  220   b . In other examples, the plastic tube  230   b  is sprayed into the wire coil  220   b .  FIGS. 4A and 4B  illustrate exemplary configurations of pipes. Other configurations and/or types of pipes and/or coatings can be utilized with the wire coil. The use of the wire coil  220   b  and the plastic tube  230   b  advantageously enables the pipe  400   b  to be strong (e.g., high compression strength, low risk of collapse, etc.) and flexible. Although  FIG. 4B  illustrates the inner plastic tube  230   b  inside the outer wire coil  220   b , the pipe  400   b  can, for example, include an outer plastic tube (not shown) and the inner plastic tube  230   b.    
       FIG. 5  is a diagram of an exemplary tunnel  510  made from a wire coil. The tunnel  510  is within a mountain  500 . As illustrated in  FIG. 5 , a vehicle  530  can travel down a road  520  through the tunnel  510 . The wire coil utilized in the tunnel  510  construction advantageously enables the tunnel to be quickly manufactured and strengthens the load bearing capabilities of the tunnel  510 . The wire coil can be, for example, the structural support for the tunnel  510 . The wire coil can be coated in protective materials (e.g., rust inhibitor, protection from water, etc.) and/or can be covered by other construction materials (e.g., concrete, asphalt, insulation, etc.). 
       FIG. 6  is a diagram of an exemplary building  600 . The building  600  includes a plurality of wire coils encased in concrete  611 ,  612 ,  613 ,  614 , and  615 . The wire coils  611 ,  612 ,  613 ,  614 , and  615  are utilized as structural supports for the building  600  and as reinforcement bars for the concrete. The wire coils utilized in the construction of the building  600  decreases the construction cost and increases the strength of the building  600 . 
     In some examples, the continuous wire coil is a unitary piece of wire (e.g., single piece, multiple pieces bonded together, etc.). In other examples, the double-spiral forms link spacing between the one or more intersecting points. 
     In some examples, the continuous wire coil is formed from a spool of wire. In other examples, the continuous wire is metal. In some examples, the continuous wire coil includes a plurality of sides. The plurality of sides is formed by a size of each of the double-spirals. 
     One skilled in the art will realize the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting of the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.