AN IMPROVED METHOD OF AND APPARATUS FOR MANUFACTURING COMPOUND TELEGRAPH WIRE
Year: 1885

page_text: I, HERBERT JOHN ALLISON, of the firm of Allison Brothers, of 52 Chancery
Lane, London, in the county of Middlesex, Patent Agents, do hereby declare the
nature of my invention for "AN IMPROVED METHOD OF AND APPARATUS FOR
MANUFACTURING COMPOUND TELEGRAPH WIRE," a communication to me from
abroad by Moses G. Farmer, Electrician, of Newport, Rhode Island, United States
of America, and in what manner the same is to be performed, to be particularly
described and ascertained in and by the following statement:-
My invention relates to the manufacture of wire for telegraphic or siinilar
purposes, composed of a steel core in a copper envelope.
Wire of this kind, as is well known, possesses many advantages over the
ordinary iron or copper wire from the fact that it combines the tensile strength of
the steel with the conductivity of copper, so that when used as a line wire it is
not only capable of sustaining a greater strain, but offers less resistance to the
current than an equal length of ordinary telegraph wire of the same diameter.
This wire has heretofore been made by wrapping a copper ribbon around a steel
core, by casting a copper tube around a steel centre and drawing both down
simultaneously, or by heavily electroplating a steel wire. But these methods or
processes of manufacture are open to many and well known objections.
Over these methods my present invention is an improvement, as by it I produce
not only a superior article, a wire that is not apt to break or corrode, but I reduce
the actual cost of manufacture.
My invention consists in first applying to a steel wire as a coro, an adherent
coating of copper by electro-deposition, and then drawing the coated wire through
molten copper, shaping the coat which it by this means acquires by passing the
wire through a suitable die. As my object in this process is chiefly to obtain a
molecular adhesion or perfect union between the steel and the enveloping
sheathing of copper, I coat the steel wire by immersing it in an electrolytic bath
of a neutral or non acid solution of copper by which a thin but perfectly adherent
coating is applied. When subsequently this wire is drawn through the molten
copper it takes up a sufficient quantity of the same to forni a conductor of low
resistance with small diameter and great tensile strength.
The mechanism which is made use of in carrying out this process, and which
forms also an important part of the invention may be considerably varied in
specific construction. One form well adapted to the purpose is a receptacle soine-
what similar in construction and composition to an ordinary smelting crucible.

page_text: This I support under the tap-hole of a furnace adapted for melting copper,
preferably by a hinge and some device by which its position can be readily
adjusted.
In the side of the receptacle is an orifice with a slightly conical nozzle and
within the receptacle is a standard or post of some refractory metal, such as
platinum or iridium, in which is an eye directly in line with the orifice.
In conjunction with this apparatus I use a blow-pipe for directing a flame into
the receptacle near the orifice, and also an apparatus without the receptacle for
forcing a blast of cool air into the nozzle.
In using this apparatus I pass a steel wire which is first coated with copper by
electro-deposition, through the eye and orifice.
Melted copper is then run into the receptacle until it rises above the orifice. The
wire is then drawn through the nozzle, cool air being forced into the latter, in
order that the copper which is drawn out with the steel core may harden at once.
When the copper is not sufficiently soft the flame of the compound blow-pipe is
directed upon it so that it may flow more freely. After issuing from the nozzle
the coated wire is drawn out on to a long table, or into a tank of water, and
allowed to cool.
In lieu of this special form of apparatus I sometimes employ a device which
consists of a tube extending through the sides of the receptacle for holding the
molten copper and provided with one or more openings or passages through the
bore of the tube. From one end of the tube to the transverse passage, the bore, in
whole or in part, is just large enough to permit the wire that is to be coated to be
drawn freely through; from the passage to the other end the bore is of somewhat
greater diameter, so that when the receptacle is filled with melted copper and a
wire drawn through the tube, the metal will be prevented from running out
through the smaller part of the bore of the tube, but a sufficient quantity will be
taken up by the wire in passing through the melted metal and carried out through
the larger part of the bore to form a strong coat that imparts a high degree of
conductivity to the conductor.
The tube constructed as set forth, constitutes the best and most practicable
means of carrying out the invention of which I am aware.
The difference in the diameters of the bore and passage through the tube,
virtually divides it into two tubes, and they may therefore be distinct, though
such construction is undesirable. The tube may extend through the receptacle
horizontally or at an angle, as may be preferred, it being only necessary to the
operation of the device that the passage for the admission of metal to the wire be
below the level of the melted metal. The diameter of the bore of the tube may
obviously not be uniform on each side of the passage, though the least diameter of
the smaller part should of course be ample to permit the free passage of the wire,
and the smallest part of the larger bore enough to allow the wire with its coating
of metal to pass.
I will now describe my invention in detail by reference to the accompanying
drawings.
Fig. 1 is a view in side elevation and part section of the apparatus.
Fig. 2 a similar view of the modified form.
Figs. 3 and 4 are sectional views of the tube or tubes in Fig. 2.
In Fig. 1, A, is a portion of a cupola or other furnace suitable for melting
copper; B, the tap-hole, and C, a lever carrying a conical plug of refractory
material for closing the tap-hole.
D, is the crucible or receptacle of refractory material. It is supported by a
binge d under the tap-hole B and provided with a rack E meshing with a gear
wheel F, by which its position or angle may be changed at will. Any other means
may be used for adjusting its position.
In the side of the receptacle D, is embedded a block e of metal, such as nickel or
platinum, in which is an orifice of a diameter equal to that of the compound wire
-

page_text: to be made. Extending from this block is a nozzle c of the same or similar metal,
the perforation through the same boing slightly conical so that the coated wire
which is drawn through it may not bind or stick to the sides.
In the receptacle D, is a post G, of nickel or platinum, having an eye directly in
line with the orifice in the block e. Above the receptacle is a roller H, in
stationary or adjustable bearings.
In using the apparatus, a wire K, of small diameter and composed by preference
of steel or tough iron, electro-coated with copper is passed under the roller H,
through the eye in post G, and taken out through the orifice and nozzle c. The
receptacle D is then filled with melted copper from the furnace and the wire drawn
through the nozzle. As it issues with the coating of copper which it takes up, a
blast of cool air is directed upon it from a nozzle L, by which means the copper
coating is set. The wire is then drawn out ou a long table M, and allowed to cool,
or it may be coiled in a tank of water.
By making the receptacle adjustable, the level of the molten copper with
reference to the orifice may be more readily adjusted than by the admission of
metal; so, too, when the wire is not passing through the orifice, the receptacle may
be tilted so that no melted copper will run out.
To prevent hardening of the copper in the receptacle and around the orifice, or to
soften it when starting the apparatus after disuse for any length of time, I mount a
compound blow-pipe N, or some similar means for generating an intense heat, above
the crucible near the orifice.
It is not necessary that the coating of copper formed on the steel wire should be
as thin as that desired for the finished wire, as it may be passed through rolls or
drawn down to the required diameter after cooling.
It is desirable that before the steel or iron core is electrically coated that it be
thoroughly cleansed in some of the ordinary ways so that it may present a clean
metallic surface for the deposition of copper. The depositing solution as above
stated should be a neutral solution as better adherence of the copper is attained in
this way. Any of the ordinary processes of electro-plating the wire may be
followed.
In the apparatus shown in Fig. 2, A, is the crucible or furnace in which the
copper or other metal to be used on the wire is melted.
Below the vent or spout B, is a ladle or receptacle C, of refractory material in
the bottom of which is a tap V of any convenient character for drawing off the
melted contents of the receptacle C, when its use is to be discontinued.
A cylinder or tube of refractory metal is passed through the sides of the
receptacle C, and secured firmly in places.
A wide passage R, is drilled through the tube on one side of which the part P,
of the tube has a larger bore than the part W, on the other side. At the opposite
ends of the tube are placed grooved rollers Q, S, and at the end of the larger bore
is also an air blast or other suitable apparatus for cooling the wire as it issues from
the tube.
In using the apparatus a wire K, preferably a steel or iron wire which has
received a thin preliminary coating of copper by electro-deposition is passed
through the two parts of the tube and run between the grooved rollers Q, S.
The receptacle C, is then filled from the spout B, with melted copper above the
level of the passage H, and the wire drawn through the tube from the part of
smaller to that of larger bore. In passing through the opening R, the wire takes
up and carries into the part P, a certain quantity of the copper. This is cooled
in passing through the tube and hardened by the air blast on issuing from
the tube.
If necessary the metal in the receptacle C, may be heated by flames directed
against the receptacle or otherwise. The apparatus constructed as now described
is more durable and less liable to get out of order than any other of which I am
aware.

page_text: Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is to be performed, I declare that what
I claim is
1st The method herein described of manufacturing compound telegraph wire,
which consists in electro-plating a steel or iron wire with a thin film of copper,
then drawing the same through molten copper and shaping the coating in
substantially the manner set forth.
2nd The method herein described of manufacturing compound telegraph wire
which consists in electro-plating a steel or iron wire with a film of copper from a
non-acid or neutral solution, then drawing the same through molten copper and
shaping by a die the coating as the wire issues from the receptacle containing the
copper in substantially the manner described.
3rd The method herein described of manufacturing compound telegraph wire
which consists in electro-plating a steel or iron wire with a film of copper, then
drawing the same through molten copper, shaping the coating by drawing the wire
through a die or orifice in the receptacle containing the copper, and cooling it as it
issues from the die or orifice, all substantially as herein set forth.
4th The combination in an apparatus for coating wire with metal of a receptacle
for containing the molten metal and provided with a die or an orifice for limiting
the amount of metal carried out through it by the wire and thus forming the coat,
a nozzle with a conical passage extending outward from the orifice, and means for
guiding a wire centrally through the orifice, all as set forth.
5th The combination in an apparatus for coating wire with metal, of a hinged or
adjustable receptacle for holding the molten metal, and provided with an orifice, a
nozzle with conical passage extending from the orifice, and meatis for guiding a
wire centrally through the orifice, all as set forth.
6th The combination with a receptacle for containing molten copper, of a block
embedded in its side and provided with an orifice, a nozzle with conical passage.
extending from the block, means for guiding a wire through the orifice, and means
for directing a blast of air upon the same as it issues therefrom, all as set forth.
7th The combination in an apparatus of the kind described of a receptacle for
containing molten metal, a perforated block e, and nozzle c, a post G, having an eye
in line with the perforation in block e, a roller H, blow pipe N, and nozzle L, for
directing an air blast into the nozzle, all as set forth.
4
8th The combination with a receptacle for containing melted metal, of a tubular
wire guide extending through the same, one portion having a bore of greater
diameter than the other, and both bores communicating with the interior of the
receptacle in substantially the manner herein set forth.
9th The combination with receptacle for containing melted metal, of a tube
extending through the same and containing a transverse passage or opening, the
bore on one side of said passage being larger than on the other, as set forth.
10th The combination with a receptacle for containing melted copper, of a tube
extending horizontally, through the same and containing a transverse passage, of
wire guide rollers located at the ends of said tube, substantially as and for the
purpose specified.