Improvements in the Manufacture of Insulated Electric Conductors, and in the Method of and Apparatus for Producing the same.
Year: 1894

page_text: Date of Application, 20th Nov., 1894-Accepted, 22nd Dec., 1894
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Insulated Electric Conductors,
and in the Method of and Apparatus for Producing the same.
1, JOHN ROBINSON, a citizen of the United States, residing at No. 5257
Green Street, Germantown, in the County of Philadelphia, and State of
Pennsylvania, Manufacturer, do hereby declare the nature of this invention and
in what manner the same is to be performed to be particularly described and
ascertained in and by the following statement:-
My invention has relation to the manufacture of electric conductors; and it
relates more particularly to the construction, arrangement and thorough insulation
thereof, as well as to the method of and apparatus for producing such a conductor.
The principal objects of my invention are first, to provide a simple, durable and
efficient insulated electric conductor; second, to provide an efficient method of
applying fibrous material, such as cotton in a raw or other state to au insulated
wire and caused to adhere thereto in such manner as to permit of the application
of a cord or thread to the covered wire and subjecting to a bath of insulating
material to constitute an insulated electric conductor; third, to provide an
economical method of insulating a wire, applying and compacting fibrous material
thereto, cording the covered wire and insulating and laying up the same; fourth, to
provide an efficient method of applying to a drawn rotatable wire fibrous material,
such as cotton or the like, in such manner as to be wrapped and compacted thereto,
winding a cord or thread in uniform layers onto the covered wire to form a
binder therefor and subjecting the same to a bath of insulating material in a molten
or other state to thoroughly insulate the same and to constitute an insulated electric
conductor; fifth, to provide a continuous method of insulating a wire, while
revolving under required tension and applying fibrous material in sheet or other
form and compacting the same thereon, cording the surface of the covered wire
and by a drawing action laying up the insulated fibrous covered and corded con-
ductor for subsequent use; and sixth, to provide suitable apparatus for carrying
into effect the method of making an insulated electric conductor of my invention.
My invention stated in general terms, consists of an insulated electric conductor
constructed and arranged in substantially the manner hereinafter described.
My invention further consists of the method of applying to an insulated wire
while in a moist or wet state fibrous material, such as cotton or the like, applying a
cord or thread thereto and subjecting the covered and corded wire to an insulating
bath and thoroughly saturating the same therewith to produce an insulated electric
conductor.
My invention further consists of the method of making an electric conductor by
continuously drawing a rotated wire through a bath of insulating material, and
while still moist, applying and compacting fibrous material thereto, then cording
the insulated and covered wire and laying up the same for subsequent treatment or
use; and
My invention further consists of apparatus for the conduct of the method of
making an electric conductor, constructed and arranged in substantially the manner
hereinafter described and claimed.
The nature and general features of my invention will be more fully understood
from the following description, taken in connection with the accompanying drawings
forming part hereof; and in which
Figure 1, is a view in elevation of an insulated electric conductor embodying the
features of my invention.

page_text: Fig. 2, is a view partly in elevation and partly in section of an apparatus adapted
for the conduct of the method of my invention.
Fig. 3, is a similar view of a modified form of apparatus for carrying into effect
my said method.
Fig. 4, is a view partly in elevation and partly in section of a still further modified
form of apparatus adapted for the conduct of the method of producing an electric
conductor of my invention.
Fig. 5, is a perspective view of the laying up reel and belt and pulley mechanism
for actuating the same and also the gear-mechanism for controlling the rotation of
the drawing-mechanism of Fig. 4.
Fig. 6, is a central longitudinal section through the wire rotating device of Fig. 4,
showing the detail construction and arrangement thereof.
Fig. 7, is a top or plan view of the wire rotating device, with its gear-mechanism
for permitting of the actuation thereof.
Fig. 8, is a central longitudinal section through the drawing-mechanism of the
machine of Fig. 4; and
Fig. 9, is a top or plan view of the same.
C,
Referring to the drawings with reference to Fig. 1, a, is a copper or other
suitable wire of good conductivity. b, is an applied coating of insulating material,
which is applied thereto by passing the wire a, through a bath of such material in
a liquid or other state. is a covering of fibrous material, such as raw cotton or
the like, applied to the coated wire a, while still moist or in a more or less wet
condition and in such manner as to present a smooth surface throughout. d, is a
series of threads or cords spirally wound around the covered wire, so as to closely
bug against one another thereon, and to present substantially a surface such as is
illustrated in Fig. 1, of the drawings. e, is a coating of insulating material applied
to the covered and corded wire by permitting the same to be conducted through a
bath of such material in a molten or other state, in order to thoroughly permeate
and saturate the said corded and covered wire; and moreover, so as to produce a
conductor of substantial efficiency for electrical purposes.
It may be here remarked that for certain uses, such as outside conductors, the
insulating covering.applied to the covered and corded insulated wire a, may have
applied thereto in any preferred manner, a braided or woven covering of fibrous or
other suitable material, not shown.
Referring now to Figs. 2 and 3, of the drawings, A, is a framework, comprising
a base a', standards a² and a³, and cross-beams at and a. B, is a reel detachably
supported to the brackets 6', which are secured to uprights a, extending from the
base a', of the said standards. The wire l, is coiled around the reel B, and is
adapted to be drawn therefrom through a bath to be presently fully explained.
C, is a tank provided with a surrounding steam coil or jacket c', mounted on a
slab c², which is secured into the base a'. This tank is provided with a cover c³,
having openings c¹ and c', therein for the travel of the wire from the reel B, around
a traveller roll or drum C2, immersed in a bath of molten material e, in the tank C.
D, is a hollow spindle secured to a support a', attached to the cross-beam a'. The
upper end of the spindle D, is formed tapering at d', for guiding fibrous material
through the opening of a cone-shaped nozzle or feeding device E, which is provided
with an integral tubular stem e', fitting the hollow spindle D, and having a flanged
or circular base e, which fits snugly against the base of a drum F, which is grooved
to form a pulley f, and secured into said base by means of screws or the like for
holding said feeding device E, firmly to position in contact with the drum F, and
in order to permit of the same being rotated therewith. The nozzle or feeding
device E, is provided with radial openings e, in the bottom and with a tapering
opening e, in the apex of the same for a purpose to be presently fully explained.
The drum or can F, and nozzle E, are rotated by means of a belt f¹, engaging the
grooved pulley f, and a double grooved pulley f2, which is mounted on a shaft f³,
and engaged by a belt f. The latter receiving its motion from any suitable source
of power, not shown. The rotatable drum or can F, is adapted to contain fibrous

page_text: material, such as cotton in a raw or other state, which is led therefrom through the
nozzle or feeding device E, to the moist, wet or sticky insulating wire drawn from
the bath, of the tank Ć, in an upward direction through the opening in the
support a', and hollow spindle D, by suitable power, not shown, and the same
caused to contact and adhere to the wire 1, in such manner as to form a continuous
smooth surface of the said material on the wire in the drawing thereof and just
beyond the point of contact of the fibrous material with the still moist or wet
insulated wire is provided a whirler G, which is supported to position by means of
a hanger g, from the cross beam a', of the structure and carrying a grooved
pulley ', adapted to be so rotated as to lay a single or a series of cords or threads
uniformly onto the covered wire . This whirler G, is provided with a series of
spindles 92 and g³, provided with spouls, bobbins or cops. The whirler G, by means
of a belt g, engaging the pulley g', and a double grooved pulley 9', and having
motion imparted thereto from any suitable source of power, is thereby rotated and
the threads or cords, as illustrated in Fig. 2, are laid onto the covered wire /, which
is drawn under proper tension and required speed in a longitudinal direction from a
drum H, supported to standards h, secured to the cross-beams a', of the structure
and from this drum the covered and corded wire 1, is conducted over a guide-roll i,
and then down through a bath of insulating material contained in a steam heated
or jacketed tank I, provided with inlet and outlet cocks and i, and a waste
cock, around a roll ¹, journaled to the walls of the tank I, and then upward and
forward between pressure rolls and , and therefrom the same is conducted onto
a reel, not shown, whereon the covered, corded and insulated wire is adapted to be
laid up as an insulated electric conductor for use. It will be observed from the
foregoing description of the apparatus for carrying my invention into effect, that
the method is continuous. It should be borne in mind that due regard should be
given to the tension of the wire and to the speed of rotation of certain of the parts
of the machine. That is to say, to the drum or can F, as well as to the devices
rotating therewith.
With reference now to Fig. 3, A', represents a carding engine of any suitable
construction, provided with a wiper or roll as, for conducting the fibrous or flaky
material to and around a rotatable cone a, journaled to standards a¹0. and all.
These standards are held in required position by means of distance rods a¹³ and a¹³.
a and a, are curved brackets secured to the standards a¹0 and a". The
standard a. and the bracket ", support the hollow spindle a, of the cone a³,
and mounted thereon is a pulley a", adapted to be engaged by a belt, not
shown, for rotating said cone at the required rate of speed with respect to the
wire 1, drawn through the spindle and cone thereof. E, is a funnel-shaped
nozzle supported in the standard a¹ and the bracket a¹, and engaging the sleeve 96,
of a whirler G', having spindles 2 and 93, carrying cops or bobbins adapted to
contain thread or cord, whereby in the rotation of the whirler by means of a
pulley secured to the sleeve g6, of the whirler, the thread or cord in regular
sequence is wound onto the covered wire 1, and preparatory to the conduct of
the said wire 1, through a bath of insulating material in the tank I, to th roughly
saturate the same and prior to its being laid up onto a rotatable reel J, as an
insulated electric conductor. The reel J, it may be here remarked is operated
by means of a hand-crank applied to one of the journals thereof or by means
of a belt and pulley connection from a suitable source of power, not shown.
and are guide rolls located above the tank C, adapted to apply an
insulating material to the wire !, from the reel B. In other respects, the
apparatus of Fig. 3, is the same as that of Fig. 2, for the carrying into effect
of the method of my invention of applying a fibrous material, such as cotton in
a raw or other state to a wire after the same has been saturated with an
insulating material, and while in a moist condition and in such manner as that at
or about the point of contact of such material with the coated wire, the fibrous
material will be caused to assume a position thereon, so as to present a perfectly
smooth surface throughout in the drawing of the wire and held thereto so as to

page_text: permit of the winding of cord or thread around the same and preparatory to the
conduct thereof through a bath of molten insulated material for effecting the
thorough insulation thereof.
With respect to the operation of the apparatus of Fig. 3, it may be here
remarked, and it will be observed, that the cotton or other fibrous material in its
travel around the cone a, is in a certain direction until it arrives at the mouth of
the funnel shaped nozzle E', whereat in the continuous drawing action of the
wire l, from the reel B, through the tank C, and between the guide rolls and 16,
and hollow spindle of the cone a', the fibrous material A³, is taken up and caused
to adhere to the moist, wet or sticky insulated wire 1, in an opposite direction to
its travel around the cone a', and in order that a uniform surface may be presented
thereto for the application of a cord or threads from the whirler G', thereto and
anterior to the saturation of said covered and corded wire l, with a liquid
insulating material in its passage through the tank I, to become an insulated
electric conductor. It will be observed that the wire 1, is continuously drawn
through the apparatus of Fig. 3, at such relative rates of speed with respect to the
delivery of the cotton or other material from the carding engine A', to the cone a³,
as to afford the necessary clearance in the nozzle E', to prevent accumulation of
the material thereat in the laying up of the same so as to present a uniform
surface on the still wet insulated wire travelling in the path thereof, by the
rotation of the reel J, by means of a hand crank or other actuating means.
Referring now to Figs. 4 to 9 inclusive, the reeling device B, is provided with
pegs or the like 62, extending from the face for supporting wire in coiled form
thereto and so as to permit of the reeling off of the same therefrom. k and k¹, are
standards, to which are journaled pulleys 2 and 3: K, is a wire rotating device
provided with hollow end journals k and ko, mounted in flanged bearings k and k²,
of standards and k, which are respectively provided at the top with lubricating
receptacles having vertical channels extending to the journals and k³. This
device K, at one end thereof is provided with a gear wheel A10, which meshes with
a gear wheel k", mounted on the main driving shaft L, of the machine. This shaft
is held to position at one portion thereof, as illustrated in Fig. 4, in the
standards, and a10, and at the other portion thereof in the standards all, 2
and ¹³. Ou the left hand end of the journal, of the wire rotating device K, is
mounted a grooved wheel k¹, and engaging therewith is a cord or chain, which
passes around the pulleys k³ and k2, and the pulley 73, of the reel B, for imparting
rotary motion thereto. The pulley, has motion imparted thereto from the main
driving-shaft L, through the intervention of the gear wheels " and k¹º, as clearly
illustrated in Fig. 4. M, is a steam jacketed tank or vat with a removable cover m.
m', is an inverted U-shaped entrance nozzle extending through the shells of the
said tank M, and m², is a V-shaped exit nozzle in the other side thereof. This
tank M, is mounted on brackets m³ and m³, secured respectively to the standards a
and, as illustrated to the left in Fig. 4, of the drawings. The wire rotating
device K, is provided with a surrounding casing 8, having two series of grooved
rolls and 20, suitably journaled in movable bearings 21 and 22, provided in the
walls of the casing 18, and with pivotally supported tightening devices k²³ and k
controlled by means of swivel connections and 2, for frictionally engaging and
disengaging said. series of rolls and 20, to and from the drawn wire 1, in its
travel between the same. In the rotation of the device K, by means of the gear
wheels and, the wire l, is revolved around and around, and at the same time
at required speed is drawn through the machine in a manner to be presently more
fully explained. A', is the carding engine or machine of any suitable construction
provided with a main driving shaft a, having a driving pulley a", at one end
thereof and adapted to be connected by means of a belt, not shown, with a driven
pulley or wheel, mounted on the main driving shaft L, of the machine. Adjacent
to the clothing of the carding engine or machine A', is located a wiper or delivery
roll as, as clearly illustrated in Fig. 4, and arranged so as to present the fibrous
material A³, to the rotated and drawn wire l, in the path of crosswise delivery of

page_text: the said material A³, thereto and in such manner as to lay and wrap said material
in spiral or similar form thereon. The standard a", is provided with a flanged
tubular bearing block a², having a vertical channel extending through the same
and in direct connection with a dish-shaped lubricating receptacle. E', is a funnel
shaped hollow spindle or nozzle projecting from the bearing block a", tapering at
the opposite end and secured to and extending into the base of a whirler or flier G',
provided with a series of spindles 92 and 9³, for the reception of bobbins or spools
for containing cord or thread.
It may be here remarked that the applied fibrous material A³, from the carding
engine A, to the constantly drawn and rotating wire l, in passage through the
nozzle E', will become compacted thereto and present a smooth surface before
reaching the whirler or flier G', for the reception of a binder therefrom. This
whirler or flier G', is provided with a grooved pulley g', arranged for a belt, not
shown, for rotating the same, from any suitable source of power, to permit in the
rotation of the wire l, of the whirler or flier G¹, laying by means of the bobbins
or spools a series of threads in regular succession onto the said covered wire 'l,
so as to present a smooth surface. N, is a wire drawing mechanism, comprising a
tapering rotatable shell n, provided at both ends with hollow journals n¹ and n²,
engaging flanged bearing blocks of the standards k¹ and k¹³, having lubricating
receptacles provided with channels leading therefrom to the hollow journals of
the device N. At one end of the shell n, to the hollow journal n³, is rigidly
mounted a gear wheel n³, and at the opposite tapering end thereof is mounted
a disc n', on the journal n¹, which is secured by means of screws to the standard k¹.
This disc n, is provided with a gear a³, which meshes with a gear nº, journaled
to one of the walls of the shell n. , is a series of similar gears occupying
staggered positions and meshing with each other and mounted on cross-shafts n³,
journaled to the respective walls of the shell n. On the series of cross-shafts n³,
are rigidily mounted two series of grooved rolls 10 and n", adapted to frictionally
contact with the corded wire l, in such manner that in the rotation of the device N,
by means of the gear-wheel n³, and its complemental gear n¹², mounted on the main
driving shaft L, the two series of rolls n' and 4, of the device N, by means of
the series of gears nº and n', in the direction of the arrows as shown in Fig. 8, will
be actuated to cause the covered and corded wire l, to be continuously drawn in a
forward direction through the several appliances of the machine hereinbefore
described. The hollow revoluble journal n², of the wire drawing mechanism N, is
extended at the right hand end and to which is secured a double grooved pulley n¹,
and a single grooved pulley n. The latter pulley carrying a nozzle or delivery
tube o, with enlarged ends and with a contracted and curved body as shown in
Figs. 4 and 5, for permitting of the delivery of the covered and corded conductor l,
drawn therethrough onto a device to be explained. j, is a standard with a
bearing, to which is detachably secured a laying up reel J, provided with pins or
stays, and with a journal, carrying a grooved pulley. The journal,
the bearing, of said standard j. p and p₁, are standards provided with grooved
pulleys p and p. p', is a cross belt engaging the pulleys n" and p², and likewise
the pulley n, and passing around the pulley p³, and pulley, of the laying up
reel J, for rotating the latter from the main driving shaft L, by means of the
gears and n³, as illustrated in Fig. 4, of the drawings.
engages
The operation of the machine of Fig. 4, as hereinbefore described, is as
follows:
The wire is drawn from the reel B, by means of the mechanism N, through
the wire rotating device K, and between the two series of frictional rolls thereof,
to and through the bath of insulating material contained in the steam jacketed
tank M, then into the presence of the fibrous material delivered in regulated
quantity from the carding engine A', and in such manner as that in the rotation
of the wire drawn in the manner hereinbefore described, the fibrous material A³,
in spiral or other form will be incorporated with and wrapped around the more or
less moist wire I, from the bath of insulating material and which is presented at

page_text: the funnel-shaped end of the nozzle E', of the whirler or flier frame G¹, drawn
therethrough and uniformly compacted to the wire prior to the laying onto the same
in regular sequence of the series of threads or cords from the flier frame or
whirler G', for instance as illustrated in Fig. 4, and then through the device N,
and the respective hollow spindles thereof to and through the delivery nozzle or
tube o, onto the laying up reel J.
It may be here remarked that after the starting of the machine, the fibrous
material is applied continuously to the rotating insulated wire l, and as well the
cord or thread to form the binder therefor, and prior to the laying up of the same
onto the reel for subsequent use, as an electric conductor. After the applying of
the wire in coiled form onto the reeling device J, it may be withdrawn therefrom
and conducted through a bath of liquid insulating material to thoroughly saturate
the same and to produce thereby, an insulated electric conductor or from the reeling
device J, the covered and corded wire may be subjected to a braiding or weaving
operation to form an outer covering therefor, which it is desirable in some cases
to provide a conductor with, for outside work.
Having now particularly described and ascertained the nature and objects of my
invention and in what manner the same is to be performed, I declare that what
I claim is :-
1. An insulated electric conductor, composed of a wire provided with a coating
of insulating material having a smooth surface covering of fibrous material, a
binder of cord or thread wound around the same and a coating of insulating
material covering and permeating said covered and corded wire, substantially as
and for the purposes set forth.
2. The method of producing an insulated electric conductor, which consists in
continuously drawing a wire through a bath of insulating material, feeding under
required tension and applying in regulated quantity cotton or the like to said wire,
while said insulating material is still wet thereon, so that said cotton or the like
may firmly adhere thereto and present a smooth and uniform surface, laying thread
or cord over the covering of said wire and conducting said wire through a bath of
insulating material to thoroughly saturate the body of the conductor, substantially
as and for the purposes set forth.
3. The method of producing an electric conductor, which consists in continuously
rotating and drawing a wire through a bath of insulating material, applying and
compacting fibrous material under required tension and in regulated quantity to
said wire and winding threads around said covered wire, substantially as and for
the purposes set forth.
4. The method of producing an electric conductor, which consists in continuously
drawing a rotated wire through a bath of insulating material and while still wet
or sticky, applying and compacting fibrous material, such as cotton or the like to
the wire, then cording the insulated and covered wire by applying threads in
regular sequence around the same and laying up the product, substantially as and
for the purposes set forth.
5. An apparatus for producing an electric conductor, comprising a reel adapted
to contain wire, means controlled from a main driving shaft for rotating said wire,
a jacketed appliance adapted to contain fluid insulating material, a carding engine
adapted to present fibrous material in the path of the moving wire, a whirler or
flier and a device connected therewith for compacting said material to said wire,
said whirler or flier adapted to lay cords or threads in regular sequence onto said
covered wire, mechanism for drawing said wire and actuated by means of gearing
from said driving shaft, a delivery nozzle or tube, a rotatable laying up reel, and
means for actuating said movable members, substantially as and for the purposes
set forth.
6. An apparatus for producing an electric conductor, comprising a rotatable reel
adapted to support wire, a main driving shaft, means for actuating said reel
controlled from said shaft, a wire rotating device, a tank adapted to contain

page_text: material for application to said wire and provided with entrance and exit nozzles
of different forms, a carding engine with a delivery appliance, a whirler or flier
with a funnel-shaped nozzle for compacting fibrous material to said wire and prior
to the cording of the same by means of said flier or whirler, a wire drawing
mechanism controlled by means connected with said driving shaft, a delivery nozzle
and winding up reel, substantially as and for the purposes set forth.
7. An apparatus for producing an insulated electric conductor, comprising a
reel, a jacketed tank provided with a rotatable roll with a removable cover having
openings therein, means for feeding under required tension and applying in
regulated quantity fibrous material to a wire adapted to be moved continuously in
the path thereof and caused to adhere thereto and present a smooth exterior
surface, a whirler or Hier, a traveller drum, a jacketed tank provided with an
internal roll, a reel, and means for actuating said movable parts, substantially as
and for the purposes set forth.
8. An apparatus for producing an insulated electric conductor, comprising a
carding engine with a wiper or roll, a rotatable cone-shaped device, a reel, a
jacketed tank provided with a revoluble roll, a nozzle, a rotatable whirler, a tank
for containing insulating material, and a winding reel, substantially as and for the
purposes set forth.
9. An apparatus for producing an insulated electric con luctor, comprising a
carding engine, a rotatable cone located adjacent thereto and provided with a
hollow spindle, a funnel-shaped feeding device, a whirler, tanks adapted to contain
insulating material and rotatable reels adapted to contain wire an 1 resultant product,
substantially as and for the purposes set forth.
10. An apparatus for producing an insulated electric conductor, comprising a
carding engine having a delivery roll or rolls, a rotatable cone located adjacent
thereto, a funnel shaped nozzle partially surrounding one portion of said cone, a
rotatable whirler, a reel, tanks adapted to contain insulating material and a
rotatable reel, substantially as and for the purposes set forth.
Dated. at Philadelphia. Pa this 26th day of October A D. 1894.
JOHN ROBINSON,
Per J. G. Lorrain, M. Inst. E.E., M. Inst. M.E.,
Chartered Patent Agent.
JOHN ROBINSON,
Per J. G. Lorrain, M. Inst. E.E., M. Inst. M.E.,
Chartered Patent Agent.