Aluminum Electrical Wire Segmented Conductor Design
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Solution Overview
Problem
Aluminum electrical wires with conductivity similar to copper conductors face challenges in maintaining a smaller outer diameter due to the larger cross-sectional area required for equivalent conductivity, leading to potential terminal insertion issues and reduced flexibility.
Innovation Solution
Concentrically twisting 19 or 37 aluminum-based core wires with a high aluminum content (not less than 99 mass %) in a non-compressed state at the same pitch, ensuring orderly alignment and a thin insulating resin covering with a thickness deviation of not less than 70%, which maintains flexibility and conductivity without increasing the wire's outer diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cross-sectional area of aluminum conductor is increased to achieve electrical conductivity similar to copper conductor, then electrical conductivity is improved, but outer diameter of electrical wire increases
Solution Approach 1:
The conductor is divided into multiple aluminum-based core wires (19 or 37 wires) that are concentrically twisted together. This segmentation allows achieving the required cross-sectional area for adequate conductivity while maintaining a compact outer diameter through efficient spatial arrangement.
Solution Approach 2:
Multiple core wires are arranged in a concentric nested structure where smaller wires are positioned within the radial arrangement of larger wires. This nesting approach maximizes the use of internal space, achieving high cross-sectional area density without increasing outer diameter.
2Reliability
If the outer diameter of electrical wire is increased to ensure adequate conductivity, then electrical conductivity is improved, but terminal insertion capability deteriorates
Solution Approach 1:
By segmenting the conductor into multiple thin core wires rather than using a single thick wire, the patent achieves the required conductivity through cumulative cross-sectional area while keeping the outer diameter small enough for terminal insertion.
Solution Approach 2:
The patent changes the structural parameters of the conductor from a solid or few-wire construction to a multi-wire construction with specific wire counts (19 or 37), optimizing the balance between conductivity and outer diameter for terminal compatibility.
3Length of stationary object
If the thickness of insulating resin covering is reduced to decrease outer diameter, then outer diameter is reduced, but manufacturing precision requirement increases
Solution Approach 1:
The segmented multi-wire conductor structure provides a more regular and compact geometry that facilitates uniform application of the insulating resin covering, reducing thickness variation and improving manufacturing precision even with thin covering.
Solution Approach 2:
By optimizing the conductor structure into specific multi-wire configurations, the patent creates geometries that are more amenable to precise insulation coating, allowing thin covering with controlled thickness deviation.
Data Source
AI summary
An aluminum electrical wire includes a conductor including aluminum-based core wires, and an insulating resin covering covering the conductor and having a thickness deviation of not less than 70%. The aluminum-based core wires contain 99 mass % of aluminum, and the conductor is constructed by concentrically twisting 19 or 37 of the aluminum-based core wires at the same pitch in a non-compressed state such that the aluminum electrical wire has a current capacity that is substantially the same as a current capacity of a copper electrical wire having a diameter that is substantially the same as a diameter of the aluminum electrical wire.