Coil forming laying head system

Abstract

A laying head assembly for the formation of coils is disclosed and can include a laying head configured to rotate about an axis, a pathway defining an enclosed conduit configured to contain an elongated material, the pathway extending in a helical path around the laying head, and at least one support structure coupling the pathway to the laying head, wherein at least one of the one or more couplings have an asymmetrical cross-sectional shape.

What is claimed is: 
     
         1 . A laying head assembly for the formation of coils comprising:
 a laying head assembly; and   a pathway defining an enclosed conduit configured to contain an elongated material, the pathway extending circumferentially around a periphery of the laying head assembly, wherein the pathway extends around the periphery through an angle of less than 180°.   
     
     
         2 . The laying head assembly of  claim 1 , wherein the pathway defines a helical shape having a non-constant radius of curvature. 
     
     
         3 . The laying head assembly of  claim 2  wherein the helical shape has an increasing radius of curvature. 
     
     
         4 . The laying head assembly of  claim 1 , wherein a portion of the interior surface defining the pathway comprises a wear resistant coating. 
     
     
         5 . The laying head assembly of  claim 4 , wherein the wear resistant coating comprises boron. 
     
     
         6 . The laying head assembly of  claim 1 , wherein the pathway comprises a plurality of segments disposed adjacent to each other and each of the segments of the plurality of segments are coupled to the laying head assembly. 
     
     
         7 . The laying head assembly of  claim 6 , wherein the at least one segment extends around the periphery of the laying head assembly through an angle of at least about 5° and not greater than 175°. 
     
     
         8 . The laying head assembly of  claim 6 , wherein at least one segment of the plurality of segments has a different length relative to another segment of the plurality of segments. 
     
     
         9 . The laying head assembly of  claim 1 , wherein the laying head assembly further comprises a split ring coupled to a laying head assembly shroud. 
     
     
         10 . The laying head assembly of  claim 9 , wherein the pathway defines a closed conduit configured to isolate the elongated material from contact with the split ring. 
     
     
         11 . A laying head assembly for the formation of coils comprising:
 a laying head assembly; and   a pathway defining a channel or a closed conduit configured to contain an elongated material, the pathway extending circumferentially around a periphery of the laying head assembly, wherein the pathway defines a helical shape having a non-constant radius of curvature.   
     
     
         12 . The laying head assembly of  claim 11 , wherein the laying head assembly further comprises a split ring coupled to a laying head assembly shroud. 
     
     
         13 . The laying head assembly of  claim 12 , wherein the pathway defines a closed conduit configured to isolate the elongated material from contact with the split ring. 
     
     
         14 . The laying head assembly of  claim 11 , wherein the helical shape has an increasing radius of curvature. 
     
     
         15 . The laying head assembly of  claim 14 , wherein the increasing radius of curvature defines a difference in radius of at least 0.5% and not greater than 50% as measured by the radius of curvature at an initial point on the pathway and a terminal point on the pathway. 
     
     
         16 . The laying head assembly of  claim 14 , wherein the increasing radius is at least 2 mm different between an initial point on the pathway and a terminal point on the pathway. 
     
     
         17 . The laying head assembly of  claim 11 , wherein a portion of the interior surface defining the pathway comprises a wear resistant coating. 
     
     
         18 . The laying head assembly of  claim 11 , wherein the pathway comprises a plurality of segments disposed adjacent to each other and each of the segments of the plurality of segments are coupled to the laying head assembly. 
     
     
         19 . The laying head assembly of  claim 18 , wherein the at least one segment extends around the periphery of the laying head assembly through an angle of at least about 5° and not greater than 175°. 
     
     
         20 . The laying head assembly of  claim 19 , wherein at least one segment of the plurality of segments has a different length relative to another segment of the plurality of segments.