Insulated conductive element having a substantially continuous barrier layer formed through multiple coatings

• US 8,726,492 B2
• Filed: 09/09/2009
• Issued: 05/20/2014
• Est. Priority Date: 09/09/2009
• Status: Expired due to Fees

• Current Assignee: Cochlear Limited
• Original Assignee: Cochlear Limited
• Inventors: Schuller, Peter, Rapsey, Jane L., Hill, Grant
• Primary Examiner(s): Vo, Peter DungBa
• Assistant Examiner(s): Carley, Jeffrey T
• Application Number:
  US12/556,338
• Publication Number:
  US 20110056726A1
• Time in Patent Office: 1,714 Days
• Field of Search: 296/05, 298/68, 298/85, 606/33, 607/116, 428/371, 428/375, 428/378, 439/447, 439/606, 156/47, 156/51, 427/117, 427/120
• US Class Current: 29/605
• CPC Class Codes: B05D 1/60 Deposition of organic layers from vapour phase vapour phase deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 7/20 to wires for insulating electric cables H01B13/16
• CPC Class Codes: C23C 14/50 Substrate holders
• CPC Class Codes: C23C 14/562 for coating elongated substrates
• CPC Class Codes: C23C 16/458 characterised by the method used for supporting substrates in the reaction chamber
• CPC Class Codes: C23C 16/545 for coating elongated substrates
• CPC Class Codes: H01B 3/308 Wires with resins
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49194 Assembling elongated conductors, e.g., splicing, etc.
• CPC Class Codes: Y10T 29/49224 with coating
• CPC Class Codes: Y10T 428/2925 Helical or coiled
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/2938 Coating on discrete and individual rods, strands or filaments

Abstract

Coating an elongate, uncoated conductive element with a substantially continuous barrier layer. The substantially continuous barrier layer is formed through relative movement of the conductive element to a frame between sequential coatings of a barrier material.

Claims

1. A method of coating an elongate, uncoated conductive element with a substantially continuous barrier layer, comprising:

positioning the uncoated conductive element on a frame comprising a plurality of spaced rods;

depositing a barrier material on the conductive element to form an intermediate layer having uncoated gaps therein located where the conductive element contacts the rods;

moving the coated conductive element relative to a frame following deposition of the intermediate layer such that the uncoated gaps are not in contact with the rods, wherein during the moving the conductive element remains substantially on the frame;

depositing a barrier material on the conductive element to form the substantially continuous barrier layer and form a coated conductive element; and

removing the coated conductive element from the frame.

2. The method of claim 1, wherein the rods are substantially parallel and wherein space between adjacent rods is substantially the same, and wherein positioning the uncoated conductive element around the plurality of rods comprises:

winding the uncoated conductive element around the rods such that turns of the wound conductive element are substantially parallel.

3. The method of claim 1, wherein depositing a barrier material on the conductive element comprises:

depositing at least one layer of parylene on the conductive element.

4. The method of claim 1, wherein the method further comprises:

winding the coated conductive element onto a spool, wherein the spooled length of the insulated conductive element is approximately equal to the length of the uncoated conductive element wound around the rods.

5. The method of claim 1, wherein positioning the uncoated elongate conductive element around the rods comprises:

manually winding the conductive element around the rods.

6. The method of claim 1, wherein positioning the uncoated elongate conductive element around the rods comprises:

winding the conductive element around the rods with a winding system.

7. The method of claim 1, wherein prior to depositing the barrier material on the conductive element, the method further comprises:

positioning the rods having the conductive element wound there around in a deposition chamber of a vapor deposition apparatus.

8. The method of claim 1, wherein prior to positioning the uncoated conductive element around the rods, the method further comprises:

positioning the rods in a deposition chamber of a vapor deposition apparatus.

9. The method of claim 1, wherein positioning the uncoated elongate conductive element around the rods comprises:

positioning an elongate single strand wire around the rods.