Method for forming and annealing an insulated conductor

1. A method of forming an insulated conductor having an insulation layer, comprising:

forming an insulated conductor to modify a cross sectional shape thereof from a substantially round cross section to a substantially rectangular cross section by drawing the insulated conductor between a pair of roller dies; then

forming the insulated conductor into a plurality of gable shaped loops by positioning the insulated conductor within a die assembly; and then after the forming of the plurality of gable shapes

heating at least a portion of the insulated conductor having the modified cross sectional shape to a selected temperature range;

maintaining the selected temperature range for at least a selected period of time thereby annealing the insulated conductor and thereby maintaining insulating properties of the insulation layer of the insulated conductor.

2. The method of forming an insulated conductor of claim 1 , wherein the method further comprises cutting the insulated conductor to a selected length.

3. The method of forming an insulated conductor of claim 1 , further comprises forming planar offsets into each of the plurality of gable shaped loops.

4. The method of forming an insulated conductor of claim 1 , wherein the heating of at least a portion of the insulated conductor to a selected temperature range and the maintaining the selected temperature range for at least a selected period of time thereby annealing the insulated conductor is repeated at least once.

5. The method of forming an insulated conductor of claim 1 , wherein the heating of at least a portion of the insulated conductor to a selected temperature range and the maintaining the selected temperature range for at least a selected period of time thereby annealing the insulated conductor further comprises an inline oven and the oven temperature is in a range of 900 to 950 degrees Fahrenheit for a time of between 47 to 67 seconds.

6. The method of forming an insulated conductor of claim 5 , wherein the oven temperature is approximately 925 degrees Fahrenheit and the time is approximately 57 seconds.

7. The method of forming an insulated conductor of claim 5 , wherein the insulated conductor is insulated with an amide/imide insulation layer and a conductor portion of the insulated conductor is made of copper.

8. The method of forming an insulated conductor of claim 1 , wherein the heating of the at least a portion of the insulated conductor to a selected temperature range and the maintaining the selected temperature range for at least a selected period of time thereby annealing the insulated conductor further comprises a batch oven and the oven temperature is in a range of 460±120 degrees F.

9. The method of forming an insulated conductor of claim 8 , wherein the selected period of time is at least about 30 minutes.

10. The method of forming an insulated conductor of claim 1 , wherein the insulated conductor is insulated with an amide/imide insulation layer and a conductor portion of the insulated conductor is made of copper and the heating does not increase a temperature of the insulation over 750 degrees F.

11. The method of forming an insulated conductor of claim 10 , wherein the heating does not increase the temperature of the insulation over 600 degrees F.

12. The method of forming an insulated conductor of claim 1 , further comprising de-spooling from a first spool and respooling onto a second spool the insulated conductor.

13. The method of forming an insulated conductor of claim 1 , further comprising cooling the insulated conductor.

14. The method of forming an insulated conductor of claim 1 wherein the heating is performed convectively.

15. The method of forming an insulated conductor of claim 1 wherein the heating is performed radiatively.

16. The method of forming an insulated conductor of claim 1 wherein the heating is performed conductively.

17. The method of forming an insulated conductor of claim 1 wherein the heating is performed inductively.