MADE | IN MINNESOTA Transforming <strong>the</strong> Future CONDUCTORS AND SHIELDING by Bill Remes Have you ever heard <strong>of</strong> a wire that is non-metallic—made without using any metal? Ever heard <strong>of</strong> a wire that would tell you in advance if it was going to fail—susceptible to breaking, cracking and shorting out? Have you ever been “te<strong>the</strong>red” to a device—your personal audio player, or an electronic medical monitoring device—and wished that <strong>the</strong> cord was just a little bit longer, or that it was capable <strong>of</strong> stretching? These are just a few <strong>of</strong> <strong>the</strong> ideas that have been developed into products for industrial applications, specifically in <strong>the</strong> medical device, aerospace and defense industries. <strong>Minnesota</strong> Wire, founded in Saint Paul, Minn., in 1972 started as a small, family-owned business in <strong>the</strong> days when wire was simply wire: made <strong>of</strong> metal, coated with rubber or plastic, fairly rigid, very heavy and thick by today’s standards. It is still family-owned and operated, but now is fully immersed in some <strong>of</strong> <strong>the</strong> highest tech applications developed in <strong>the</strong> United States and around <strong>the</strong> world. Particularly in <strong>the</strong> areas <strong>of</strong> medical device and military/aerospace. <strong>Minnesota</strong> Wire also is <strong>the</strong> largest producer <strong>of</strong> hearing aid wire in <strong>the</strong> United States. <strong>Minnesota</strong> Wire’s Chairman/CEO Paul Wagner recently introduced me to three <strong>of</strong> <strong>the</strong>ir newer products that have shown tremendous early signs <strong>of</strong> success and acceptance into many applications. The key to all three <strong>of</strong> <strong>the</strong>se technologies is that <strong>the</strong>y are all very lightweight and, virtually, or in some cases, completely non-metallic. The need to minimize weight in defense applications is one <strong>of</strong> <strong>the</strong> main drivers <strong>of</strong> this technology. An actual image <strong>of</strong> a six-conductor elastomeric wire—simply called “stretchy wire”—which can stretch up to 200 percent with no electrical signal degradation. 1. Carbon nanotube (CNT) wire uses nanotubes <strong>of</strong> extruded carbon, arranged in a continuous string. It is <strong>the</strong>n wound and shielded by a variety <strong>of</strong> different materials for strength and added conductivity, such as Teflon and gold, and extruded with jackets <strong>of</strong> various polymers and plastics. This nanotechnology allows for <strong>the</strong> production <strong>of</strong> wiring, capable <strong>of</strong> transmitting signals at very high frequencies and at very fast speeds. In <strong>the</strong> medical field, nonmetallic CNT wire works as carbon fiber did in <strong>the</strong> past—allowing for complete radio-translucence. This is great for X-rays, where wires need to be invisible. 2. Prognostic Health Management (PHM) or “smart wire” is designed to indicate <strong>the</strong> exact locations <strong>of</strong> faults (opens and shorts, for instance) in live circuits (in-situ). In addition, when data is ga<strong>the</strong>red overtime, it provides a prognostic ability. This allows for replacement <strong>of</strong> wire before it becomes a safety risk or operational impediment in critical applications. PHM uses both “smart connector” technology, with in-line connectors, and ultra-thin CNT “sacrificial layers.” These sacrificial layers are embedded with three specific layers not used in <strong>the</strong> transmission <strong>of</strong> signals: a conductive layer, on top <strong>of</strong> a non-conductive layer, which is <strong>the</strong>n on top <strong>of</strong> ano<strong>the</strong>r conductive layer. Any breakdown <strong>of</strong> <strong>the</strong>se three layers serves as a “fatigue” warning that <strong>the</strong> wire is potentially going to fail and is in need <strong>of</strong> replacement. Designed and intended for very high reliability applications, this product is being well received in aerospace, medical, and utility process control applications, only to name a few. 3. Elastomeric wiring and shielding or “stretchy wire” provides <strong>the</strong> ability to stretch up to 200 percent, without any degradation in <strong>the</strong> signals being transmitted or in <strong>the</strong> integrity <strong>of</strong> <strong>the</strong> wire, from your personal audio player to an electronic medical device—all can utilize this product and technology. Currently under development is a version <strong>of</strong> this stretchy wire which can withstand repeated washings (wire that is embedded in a shirt, for example, with leads and wires in <strong>the</strong> fabric that can monitor pulse rate, heartbeat, body temperature, etc.). As Wagner said, “Driving technology manufacturing is not only smart and pr<strong>of</strong>itable, it is crucial to your kid’s next job.” Saint Paul and <strong>Minnesota</strong> are “wired in” to <strong>the</strong> forefront <strong>of</strong> technology in <strong>the</strong> United States as designed and built by <strong>Minnesota</strong> Wire. PM Bill Remes is vice president, sales & marketing for AmeriStar <strong>Manufacturing</strong> Inc. in Mankato, Minn. He can be reached at billr@ameristarmfg.com. sponsored by | HEGMAN MACHINE TOOL INC. 20 | PRECISION MANUFACTURING July | August 2010
IPM sPecIalIzes In PrecIsIon cnc MachInIng and gear cuttIng for oeM’s In a wIde varIety <strong>of</strong> IndustrIes. ISO9001:2000 p: 320-656-1241 | f: 320-656-1242 email: info@ipminc.com | ipminc.com P.o. Box 309, waite Park, Mn 56387 © 2007 IPM Inc. All Rights Reserved July | August 2010 PRECISION MANUFACTURING | 21
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