Wire fabricator

Abstract

A wire fabrication apparatus includes a number of fluid channels, each fluid channel configured to receive a first portion of a corresponding wire of a number of wires and including a fluid flowing in a first direction therein. A twisting mechanism is configured for attachment to second portions of the number of wires, the twisting mechanism being configured to draw the number of wires from the number of fluid channels in a second direction opposite to the first direction and to twist the number of drawn wires. A controller controls twisting mechanism to form a twisted wire, including controlling the twisting mechanism to draw the number of wires from the number of fluid channels in the second direction and to twist the drawn wire.

What is claimed is: 
     
         1 . A wire fabrication apparatus comprising:
 a plurality of fluid channels, each fluid channel configured to receive a first portion of a corresponding wire of a plurality of wires and comprising a fluid flowing in a first direction therein;   a twisting mechanism configured for attachment to second portions of the plurality of wires, the twisting mechanism being configured to draw the plurality of wires from the plurality of fluid channels in a second direction opposite to the first direction and to twist the plurality of drawn wires; and   a controller for controlling the twisting mechanism to form a twisted wire, including controlling the twisting mechanism to draw the plurality of wires from the plurality of fluid channels in the second direction and to twist the drawn wire.   
     
     
         2 . The wire fabrication apparatus of  claim 1  wherein the twisting mechanism comprises:
 a motor including a rotatable attachment head for attachment to second portions of the plurality of wires; and 
 a separator for changing a distance between the plurality of fluid channels and the motor; 
 wherein controlling the twisting mechanism to form the twisted wire further comprises,
 controlling the separator to increase the distance between the motor and the plurality of fluid channels to draw the plurality of wires from the plurality of fluid channels in the second direction, and 
 controlling motor to twist the plurality of wires by rotating the attachment head. 
 
 
     
     
         3 . The wire fabrication apparatus of  claim 1  wherein the controller is further configured to control flow properties of the fluid flowing through the plurality of fluid channels to adjust a drag force acting on the plurality of wires in the plurality of fluid channels. 
     
     
         4 . The wire fabrication apparatus of  claim 3  wherein the flow properties of the fluid are controlled by adjusting one or more parameters including velocity of the fluid in the fluid channels and a viscosity of the fluid in the channels. 
     
     
         5 . The wire fabrication apparatus of  claim 4  wherein the controller is configured to adjust a velocity of the fluid in the fluid channels relative to a velocity of the wires in the fluid channels. 
     
     
         6 . The wire fabrication apparatus of  claim 1  further comprising a propulsion mechanism for causing the fluid to flow in the plurality of fluid channels. 
     
     
         7 . The wire fabrication apparatus of  claim 1  wherein at least a portion of each wire of the plurality of wires has a diameter less than or equal to 10 μm. 
     
     
         8 . The wire fabrication apparatus of  claim 1  wherein controlling the twisting mechanism to draw the plurality of wires from the plurality of fluid channels in the second direction and to twist the drawn wire includes controlling a linear velocity of the motor in the second direction and a rotational velocity of the motor. 
     
     
         9 . A wire fabrication method comprising:
 positioning, for each wire of a plurality of wires, a first portion of the wire in a corresponding fluid channel of a plurality of fluid channels, each fluid channel comprising a fluid flowing in a first direction therein;   drawing the plurality of wires from the plurality of fluid channels in a second direction opposite to the first direction; and   twisting the plurality of drawn wires using a twisting mechanism to form a twisted wire.   
     
     
         10 . The wire fabrication method of  claim 9  wherein twisting the plurality of drawn wires includes:
 rotating an attachment head of a motor, the attachment head being attached to the plurality of wires; and 
 changing a distance between the plurality of fluid channels and the motor. 
 
     
     
         11 . The wire fabrication method of  claim 10  wherein controlling the twisting mechanism to draw the plurality of wires from the plurality of fluid channels in the second direction and to twist the drawn wire includes controlling a linear velocity of the motor in the second direction and a rotational velocity of the motor. 
     
     
         12 . The wire fabrication method of  claim 9  further comprising controlling flow properties of the fluid flowing through the plurality of fluid channels to adjust a drag force acting on the plurality of wires in the plurality of fluid channels. 
     
     
         13 . The wire fabrication method of  claim 12  wherein the flow properties of the fluid are controlled by adjusting one or more parameters including velocity of the fluid in the fluid channels and a viscosity of the fluid in the channels. 
     
     
         14 . The wire fabrication method of  claim 9  further comprising adjusting a velocity of the fluid in the fluid channels relative to a velocity of the wires in the fluid channels. 
     
     
         15 . The wire fabrication method of  claim 9  further comprising causing the fluid to flow in the plurality of fluid channels using a propulsion mechanism. 
     
     
         16 . The wire fabrication method of  claim 9  wherein at least a portion of each wire of the plurality of wires has a diameter less than or equal to 10 μm. 
     
     
         17 . The wire fabrication method of  claim 9  further comprising preparing the plurality of wires including, for each wire of the plurality of wires:
 attaching the wire to a substrate using a soluble adhesive; and 
 attaching one end of the wire to an attachment member using a permanent adhesive. 
 
     
     
         18 . The wire fabrication method of  claim 17  wherein a dimension of the attachment member is greater than a diameter of the wire. 
     
     
         19 . The wire fabrication method of  claim 18  wherein the dimension of the attachment member is one or more orders of magnitude greater than the diameter of the wire. 
     
     
         20 . The wire fabrication method of  claim 17  wherein the soluble adhesive is water-soluble. 
     
     
         21 . The wire fabrication method of  claim 17  wherein the attachment member includes a ferromagnetic disk dimensioned such that it is incapable of passing through a fluid channel of the plurality of fluid channels.