Claims
- 1. A brush stock comprising:
plural conductive elements including at least one of plural conductive fibers and plural conductive strands of fibers; and said conductive elements having contacting engagements with each other with the contacting engagements maintaining elastic stresses between said conductive elements and maintaining voids between said conductive elements.
- 2. A brush stock comprising:
plural conductive elements including at least one of plural conductive fibers and plural conductive strands of fibers; and said conductive elements having contacting engagements interconnected by fixed in shape segments of said conductive elements maintaining voids between said conductive elements.
- 3. The brush stock according to claims 1 or 2, further comprising:
at least one of a surface layer, a casing, and a sheath covering at least a part of a surface of said brush stock.
- 4. The brush stock according to claim 3, wherein a mechanical strength per unit area of said at least one of said surface layer, said casing, and said sheath exceeds by at least 15% an average mechanical strength per unit area of the conductive elements and said voids adjacent to said at least one of said surface layer and said sheath.
- 5. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath differs from the conductive elements adjacent to said at least one of said surface layer, said casing, and said sheath in chemical composition.
- 6. The brush stock according to claim 3, wherein a mechanical stiffness of an average conductive element in said at least one of said surface layer, said casing, and said sheath is at least 10% larger than that of corresponding conductive elements adjacent to said at least one of said surface layer, said casing, and said sheath.
- 7. The brush stock according to claims 1 or 2, comprising:
a shape of a form having at least one part.
- 8. The brush stock according to claims 1 or 2, comprising: stitching provided between said conductive elements fixing a shape to said brush stock.
- 9. The brush stock according to claim 8, wherein said stitching comprises metal fibers.
- 10. The brush stock according to claims 1 or 2, further comprising:
said brush stock having an average packing fraction f, defined as the ratio of the total cross-sectional area of said conductive elements relative to the total cross-sectional area of the brush stock, within a range of 2% to 70%.
- 11. The brush stock according to claims 1 or 2, comprising:
said conductive elements having bends which define at least one of a regular or irregular spiral pattern, a regular or irregular wavy pattern, a regular or irregular saw-tooth pattern, a regular or irregular triangular pattern, a regular or irregular rectangular pattern, and a regular or irregular undulating pattern along a length of said conductive elements.
- 12. The brush stock according to claim 11, wherein said bends are spaced at intervals along the length of said conductive elements.
- 13. The brush stock according to claim 11, wherein said bends are spaced at intervals greater than five diameters of said conductive elements along the length of said conductive elements.
- 14. The brush stock according to claims 1 or 2, wherein said conductive elements have a diameter less than 0.2 mm.
- 15. The brush stock according to claims 1 or 2, wherein said conductive elements comprise a material selected from the group consisting of at least one metal, at least one form of carbon, at least one semiconductor, and at least one form of plastic.
- 16. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises an average packing fraction which is greater than an average packing fraction of the conductive elements adjacent to said at least one of said surface layer, said casing, and said sheath.
- 17. The brush stock according to claim 3, wherein said surface layer comprises an infiltrated material.
- 18. The brush stock according to claim 17, wherein said infiltrated material is selected from the group consisting of a metal, a lubricant, and an abrasive.
- 19. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises at least one of a foil and a metal leaf.
- 20. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises at least one turn of at least one of a foil strip, a metal leaf strip, and a metal fiber.
- 21. The brush stock according to claim 19, wherein said foil is at least partly made of a metal.
- 22. The brush stock according to claim 21, wherein said metal comprises at least one of cadmium, copper, indium, iron, nickel, niobium, tin, a noble metal, cadmium alloy, copper alloy, indium alloy, iron alloy, nickel alloy, niobium alloy, a noble metal alloy and tin alloy.
- 23. The brush stock according to claim 20, wherein said foil strip is at least partly made of a metal.
- 24. The brush stock according to claim 23, wherein said metal comprises at least one of cadmium, copper, indium, iron, nickel, niobium, tin, a noble metal, cadmium alloy, copper alloy, indium alloy, iron alloy, nickel alloy, niobium alloy, a noble metal alloy and tin alloy.
- 25. The brush stock according to claim 20, wherein said metal fiber comprises at least one of cadmium, copper, indium, iron, nickel, niobium, tin, a noble metal, cadmium alloy, copper alloy, indium alloy, iron alloy, nickel alloy, niobium alloy, a noble metal alloy and tin alloy.
- 26. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises at least two fibers alternatively wrapped around said brush stock at different orientations.
- 27. The brush stock according to claim 26, wherein said orientations comprise angles between ±20 degrees and ±90 degrees relative to a brush stock longitudinal axis.
- 28. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises at least two foil strips alternatively wrapped around said brush stock at different orientations.
- 29. The brush stock according to claim 28, wherein said orientations comprise angles between ±20 degrees and ±90 degrees relative to a brush stock longitudinal axis.
- 30. The brush stock according to claim 26, wherein said at least two fibers comprise fibers selected from the group consisting of cadmium, copper, indium, iron, nickel, niobium, tin, a noble metal, cadmium alloy, copper alloy, indium alloy, iron alloy, nickel alloy, niobium alloy, a noble metal alloy and tin alloy.
- 31. The brush stock according to claim 26, wherein said at least two fibers comprise fibers plated with a metal.
- 32. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises a predetermined size and shape.
- 33. The brush stock according to claims 1 or 2, wherein said contacting engagements of said conductive elements comprise bonded contacting engagements formed by at least one of the group consisting of soldering, welding, electroplating, electrophoresis, plasma spraying, thermally spraying, irradiation and heating said contacting engagements.
- 34. The brush stock according to claim 3, wherein said at least one of said surface layer, said casing, and said sheath comprises bonded contacting engagements within a peripheral layer of said brush stock formed by at least one of the group consisting of soldering, welding, electroplating, electrophoresis, plasma spraying, thermally spraying, irradiation and heating said contacting engagements.
- 35. The brush stock according to claims 1 or 2, further comprising:
a filler material between said conductive elements.
- 36. The brush stock according to claim 35, wherein said filler material comprises at least one of a strengthening material, an abrasive material, a lubricating material, and a polishing material.
- 37. The brush stock according to claim 36, wherein said filler material is selected from the group consisting of graphite, MoS2, metal, semiconductor, plastic and any mixtures thereof.
- 38. The brush stock according to claim 36, wherein said lubricant comprises at least one of an oil and a solution of a colloidal graphite.
- 39. The brush stock according to claims 1 or 2, further comprising:
support fibers substantially more rigid than said conductive elements mixed within said conductive elements and mechanically strengthening said brush stock.
- 40. The brush stock according to claims 1 or 2, wherein said conductive elements comprise at least one of a cadmium fiber, a cadmium alloy fiber, a copper fiber, a copper alloy fiber, a silver fiber, a silver alloy fiber, a silver-plated copper fiber, a silver-plated copper alloy fiber, a cadmium-plated silver fiber, a gold-plated copper fiber, a gold-plated copper alloy fiber, a copper-plated silver fiber, a copper-plated silver alloy fiber, a gold fiber, a copper-plated gold fiber, a silver-plated gold fiber, a nickel-plated gold fiber, a copper-plated gold alloy fiber, a silver-plated gold-alloy fiber, a nickel-plated gold alloy fiber, a nickel-plated copper fiber, a nickel-plated copper alloy fiber, rhodium plated gold fiber, a rhodium plated gold alloy fiber, a platinum plated copper fiber, a platinum-plated copper-alloy fiber, a zirconium-plated copper fiber, a chromium-plated copper fiber, and a gold-nickel-plated copper fiber.
- 41. In a method of making a brush stock, the improvement comprising:
arranging plural conductive elements including at least one of plural conductive fibers and plural conductive strands of fibers in contacting engagement with each other with the contacting engagement maintaining said conductive elements under elastic stresses to maintain voids between said conductive elements.
- 42. In a method of making a brush stock, the improvement comprising:
arranging plural conductive elements including at least one of plural conductive fibers and plural conductive strands of fibers in contacting engagement interconnected by fixed in shape segments of said conductive elements to maintain voids between said conductive elements.
- 43. The method of claims 41 or 42, further comprising:
providing conductive elements having plural bends along a length of said conductive elements in contacting engagement.
- 44. The method of claims 41 or 42, further comprising:
covering at least a part of a peripheral surface of said brush stock with at least one of a surface layer, a casing, and a sheath to maintain said conductive elements under elastic stress.
- 45. The method of claims 41 or 42, further comprising:
covering at least a part of a peripheral surface of said brush stock with at least one of a surface layer, a casing, and a sheath to provide a protective covering to said conductive elements.
- 46. The method of claims 41 or 42, further comprising:
compressing said arranged conductive elements in a form of predetermined size and shape.
- 47. The method of claim 45, further comprising:
simultaneously heating said conductive elements while compressing said conductive elements.
- 48. The method of claim 45, further comprising:
stitching said conductive elements together to a desired shape.
- 49. The method of claims 41 or 42, comprising:
providing conductive elements having bends formed by crimping, kinking, waving, spiraling, pleating, folding, and curling said conductive elements.
- 50. The method of claims 41 or 42, wherein said arranging step comprises:
placing a layer of said conductive elements on a thin metal foil; and rolling up the thin metal foil with said layer of said conductive elements placed thereon.
- 51. The method of claims 41 or 42, wherein said arranging step comprises:
rolling up said conductive elements.
- 52. The method of claims 41 or 42, wherein said arranging step comprises at least one of the steps of twisting, felting, roping, matting, spiraling, braiding, interweaving and interlinking said conductive elements.
- 53. The method of claims 41 or 42, further comprising:
partially filling spaces between said conductive elements with at least one of a strengthening material, a lubricating material, a polishing material, and an abrasive material.
- 54. The method of claim 44, further comprising:
heating said brush stock to a melting-point temperature of at least one component of said at least one of said surface layer and said sheath.
- 55. The method of claims 41 or 42, further comprising:
inserting said brush stock into a casing of predetermined size and shape.
- 56. The method of claim 44, further comprising:
heating said brush stock to a melting-point temperature of an alloy formed of at least two chemical constituents of said at least one of said surface layer, said casing, and said sheath.
- 57. The method of claims 41 or 42, further comprising:
dipping or rolling said brush stock into a powder-mixture comprising a constituent of a metallic eutectic; heating said brush stock to a melting-point temperature of said metallic eutectic; and cooling said brush stock.
- 58. The method of claims 41 or 42, further comprising:
spraying at least a portion of an exterior of said brush stock with a strengthening material.
- 59. The method of claims 41 or 42, further comprising:
heating said brush stock to induce local melting or eutectic formation at interconnections of said conductive elements.
- 60. The method of claims 41 or 42, further comprising:
irradiating said brush stock to induce local melting or eutectic formation at interconnections of said conductive elements.
- 61. The method of claims 41 or 42, further comprising:
eutectically bonding said contacting engagements of said conductive elements.
- 62. The method of claims 41 or 42, further comprising:
cutting a brush of a desired length from said brush stock.
- 63. The method of claims 41 or 42, further comprising:
shaping an end of said brush stock to a desired shape.
- 64. The method of claim 63, further comprising:
sliding said end of said brush stock against an abrading material shaped to conform to shape of an intended rotor or other substrate surface.
- 65. The method of claim 62, wherein said cutting step comprises:
infiltrating at least a portion of one end of said brush stock with a hardenable or reezable liquid; hardening or freezing said liquid; cutting said brush stock; and dissolving or melting and removing said liquid from said brush stock.
- 66. The method of claims 41 or 42, wherein said arranging step comprises:
mixing support fibers in between said conductive elements.
- 67. The method of claims 41 or 42, further comprising:
introducing a component into the brush stock; and heating said brush stock to diffuse said component into said conductive elements.
- 68. The method of claim 67, wherein said component comprises at least one of a foil and a powder.
- 69. A conductive brush loading device comprising:
a hydrostatically controlled brush holder mounting a conductive brush; a hydrostatic fluid comprising a conductive fluid coupled under pressure to said brush holder to apply pressure to said brush; and electrical connections between said conductive fluid and a current supply and between the conductive fluid and the brush.
- 70. The loading device according to claim 69, wherein said conductive fluid comprises a liquid metal.
- 71. The loading device according to claim 69, wherein said conductive fluid comprises at least one of mercury, NaK sodium-potassium eutectic, and gallium heated mildly above room temperature.
- 72. The loading device according to claim 69, wherein said brush holder comprises:
a flexible bellows having an inlet coupled to a source of said hydrostatic fluid; and a conductive plate at one end of the bellows, on which said brush is supported, movably mounted at one end of said bellows.
- 73. The loading device according to claim 72, wherein said bellows comprises a material selected from the group consisting of metal, ceramic, and plastic material.
- 74. The loading device according to claim 69, wherein said brush holder comprises:
a hydraulic cylinder having- an inlet coupled to a source of said hydrostatic fluid; and a piston, on which said brush is supported, movably mounted in said hydraulic cylinder.
- 75. The loading device according to claim 74, wherein said hydraulic cylinder comprises a material selected from the group consisting of metal, ceramic, and plastic material.
- 76. The loading device according to claim 74, wherein said hydraulic cylinder comprises an inlet for the supply of at least one of moisture, lubricant, protective atmosphere, and coolant.
- 77. The loading device according to claim 74, wherein said hydraulic cylinder comprises an outlet for exhausting a substance from said hydraulic cylinder.
- 78. The loading device according to claim 69, wherein said brush comprises:
plural conductive elements including at least one of plural conductive fibers and plural conductive strands of fibers; and said conductive elements arranged in contacting engagement with each other under elastic stress to maintain voids between said conductive elements.
- 79. The loading device according to claim 78, wherein said conductive elements have bends along a length thereof.
- 80. The loading device according to claim 78, wherein said brush has an average packing fraction f, defined as the ratio of the total cross-sectional area of said conductive elements relative to the cross-sectional area of said brush, within a range of 2% to 70%.
- 81. The loading device according to claim 80, wherein said packing fraction, f is within a range of 10% to 20%.
- 82. The loading device according to claim 79, wherein said bends define at least one of a regular or irregular spiral pattern, a regular or irregular wavy pattern, a regular or irregular saw-tooth pattern, a regular or irregular triangular pattern, a regular or irregular rectangular pattern, and a regular or irregular undulating pattern along the length of the conductive elements.
- 83. The loading device according to claim 78, wherein said conductive elements have a diameter less than 0.2 mm.
- 84. The loading device according to claim 78, wherein said conductive elements comprise at least one of a cadmium fiber, a cadmium alloy fiber, a copper fiber, a copper alloy fiber, a silver fiber, a silver alloy fiber, a silver-plated copper fiber, a silver-plated copper alloy fiber, a cadmium-plated silver fiber, a gold-plated copper fiber, a gold-plated copper alloy fiber, a copper-plated silver fiber, a copper-plated silver alloy fiber, a gold fiber, a copper-plated gold fiber, a silver-plated gold fiber, a nickel-plated gold fiber, a copper-plated gold alloy fiber, a silver-plated gold-alloy fiber, a nickel-plated gold alloy fiber, a nickel-plated copper fiber, a nickel-plated copper alloy fiber, rhodium plated gold fiber, a rhodium plated gold alloy fiber, a platinum plated copper fiber, a platinum-plated copper-alloy fiber, a zirconium-plated copper fiber, a chromium-plated copper fiber, and a gold-nickel-plated copper fiber.
- 85. The loading device according to claim 78, wherein said conductive elements comprises at least one of a noble metal fiber, a noble metal alloy fiber, a fiber plated with a noble metal, and a fiber plated with a noble metal alloy.
- 86. The loading device according to claim 78, further comprising at least one of a surface layer, said casing, and sheath covering at least part of a surface of said brush.
- 87. The loading device according to claim 78, wherein said contacting engagements of said conductive elements comprise soldered or welded contacting engagements.
- 88. The loading device according to claim 78, wherein said contacting engagements of said conductive elements comprise soldered contacting engagements within a peripheral layer of said brush.
- 89. The loading device according to claim 78, further comprising:
a filler material between said conductive elements.
- 90. The loading device according to claim 89, wherein said filler material comprises at least one of a strengthening material, an abrasive material, a lubricating material, and a polishing material.
- 91. A conductive brush loading device for loading a flexible brush stock, comprising:
a shell used for containing and guiding the brush stock, said shell having an opening to allow a free end of the brush stock to exit said shell; and a conductive rotatable lever, contained within said shell, having a first end connected to a power supply and a second end connected to said brush stock at an end opposite of said free end of the brush stock, wherein said lever rotates to guide said free end of said brush stock to exit said shell through said opening.
- 92. A conductive brush loading device for loading a flexible brush stock, comprising:
a shell used for containing and guiding the brush stock, said shell having an opening to allow a free end of the brush stock to exit said shell, wherein said brush stock contained within said shell has a first end at an end opposite of said free end connected to a power supply, and wherein an elasticity of said brush stock guides said free end of said brush stock to exit said shell through said opening.
- 93. The loading device according to claims 91 or 92, wherein said shell comprises a circular shape.
- 94. The loading device according to claims 91 or 92, further comprising:
a fastener connected to said shell to secure said shell in place.
Government Interests
[0001] This invention was made in part by funds provided by the U.S. Department of the Navy. The U.S. Government may therefore have certain rights in the invention
Provisional Applications (1)
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Number |
Date |
Country |
|
60014753 |
Apr 1996 |
US |
Divisions (1)
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Number |
Date |
Country |
Parent |
09147100 |
Feb 1999 |
US |
Child |
09859472 |
May 2001 |
US |