Stranded Conductor with Alternating Copper Steel Layers
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Solution Overview
Problem
Existing electrical conductors with steel wire layers for tensile strength compromise flexibility and corrosion resistance when sealed with crimp connections, leading to longitudinal channels that cause corrosion and reduced flexibility.
Innovation Solution
A stranded conductor design featuring a central copper core wire with alternating copper and high-tensile strength steel wires in the first layer and an outer layer of copper wires, allowing for increased flexibility and gas-tight sealing without compromising tensile strength, using a copper matrix for secure crimp connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a closed steel wire layer is arranged over the core wire to achieve high tensile strength, then tensile strength is improved, but flexibility deteriorates and corrosion resistance worsens due to longitudinal channels
Solution Approach 1:
The patent applies local quality by differentiating the material composition at different radial positions within the conductor. The inner layers (first through fourth wire layers) contain steel wires for tensile strength, while the outer fifth layer contains only copper wires. This local differentiation allows the conductor to have high tensile strength from the steel wires while maintaining flexibility and corrosion resistance at the outer surface where it contacts the environment.
2Strength
If a closed steel wire layer is arranged over the core wire to achieve high tensile strength, then tensile strength is improved, but corrosion resistance deteriorates due to longitudinal channels
Solution Approach 1:
The patent applies local quality by differentiating the material composition at different radial positions within the conductor. The inner layers (first through fourth wire layers) contain steel wires for tensile strength, while the outer fifth layer contains only copper wires. This local differentiation allows the conductor to have high tensile strength from the steel wires while maintaining flexibility and corrosion resistance at the outer surface where it contacts the environment.
3Ease of operation
If alternating copper and steel wires are arranged in the first layer to maintain flexibility, then flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the conductor into five distinct wire layers with specific compositions. The first layer alternates copper and steel wires (e.g., Cu-St- Cu-St- Cu-St- Cu-St- Cu-St pattern), while subsequent layers have specific compositions. This segmented structure allows systematic control of flexibility and tensile strength properties while providing a clear manufacturing framework.
Solution Approach 2:
The patent applies asymmetry in the radial distribution of materials, with steel wires concentrated in inner layers and copper wires dominating outer layers. This asymmetric arrangement optimizes the balance between tensile strength (from inner steel wires) and flexibility/corrosion resistance (from outer copper wires), creating a non-uniform but functionally optimized structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves high flexibility, tensile strength, and corrosion resistance with reliable electrical contact, suitable for applications requiring small dimensions, such as automotive and aviation, while maintaining consistent volume resistance and preventing corrosion.
Implementation Method 1
deformation of the softer copper wires fills all cavities in the conductor down to the core wire
Implementation Method 2
the copper matrix provides an extremely good and permanent electrical contact connection to the surrounding connection part
Data Source
Figure 1~2
AI summary
In a tensile-resistant electrical conductor consisting of a central core wire and at least two wire layers arranged above the core wire, an inner first wire layer is arranged above the central core wire (2) made of copper or a copper alloy. This first layer consists of a circumferentially alternating sequence of copper wires (3) and steel wires (4). The outer second or any subsequent wire layer consists exclusively of copper wires (5) (Fig. 1).