Audio Video Cable Soft Dilute Copper Alloy Conductor
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Solution Overview
Problem
Audio/video cables require a conductor material that balances high conductivity with flexibility and resistance to bending forces, as traditional hard copper wires are prone to deformation and breakage, while soft copper wires with optimal crystal grain structure are difficult to process and maintain sound/image quality.
Innovation Solution
Development of a soft dilute copper alloy material with a recrystallized structure, where the surface layer has smaller crystal grains than the internal grains, and an average crystal grain size within 20 μm depth, incorporating additives like Ti, Mg, or Zr to enhance conductivity and flexibility, and sulfur and oxygen to control softening temperature and precipitation of impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard copper wire is used to maintain high conductivity and long crystal grain structure, then conductivity is improved, but the cable becomes rigid and prone to deformation and breakage under repeated bending forces
Solution Approach 1:
The patent applies local quality by creating a dual-zone crystal grain structure: a surface layer with fine crystal grains (≤20 μm) to provide flexibility and bending resistance, and an internal core with larger crystal grains to maintain conductivity. This spatial differentiation of crystal grain sizes allows the cable to simultaneously achieve both flexibility and high conductivity without compromising either property.
2Strength
If soft copper wire is used to improve flexibility and bending resistance, then flexibility is improved, but the crystal grain structure becomes uniform and small, increasing transmission loss and deteriorating sound and image quality
Solution Approach 1:
The patent resolves this contradiction by implementing local quality through a differentiated crystal grain structure. The surface layer contains fine crystal grains to ensure flexibility and bending resistance, while the internal core maintains larger crystal grains to minimize transmission loss and preserve sound and image quality. This spatial variation in crystal grain characteristics allows the soft copper wire to simultaneously achieve both flexibility and high transmission quality.
3Strength
If uniform small crystal grains are created throughout the wire to improve flexibility, then flexibility is improved, but the number of crystal grain boundaries increases, increasing transmission loss
Solution Approach 1:
The patent applies local quality by creating a non-uniform crystal grain structure where the surface layer has fine crystal grains (≤20 μm) to provide flexibility, while the internal core has larger crystal grains to reduce the number of crystal grain boundaries and minimize transmission loss. This spatial differentiation ensures that flexibility is achieved locally at the surface without compromising overall transmission efficiency.
4Reliability
If traditional OFC or TPC is used to maintain long crystal grains for low transmission loss, then transmission quality is improved, but the material becomes difficult to process and maintain consistent crystal structure after forming
Solution Approach 1:
The patent applies parameter changes by precisely controlling the crystal grain size parameters in different regions of the wire. The surface layer is engineered with crystal grains of ≤20 μm while the internal core maintains larger grains. This parameter differentiation, achieved through controlled cooling and heat treatment processes, allows the material to be easily processed into flexible cables while maintaining consistent crystal structure and low transmission loss.
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 solution provides an audio/video cable with high conductivity, long bending life, and improved flexibility, maintaining sound and image quality by reducing crystal grain boundaries and enhancing processing ease, while maintaining a crystal structure with larger internal grains than traditional OFC cables.
Implementation Method 1
incorporating additives like Ti, Mg, or Zr to enhance conductivity and flexibility, and sulfur and oxygen to control softening temperature and precipitation of impurities
Implementation Method 2
the soft dilute copper alloy material comprises a recrystallized structure having a grain size distribution such that crystal grains in a surface layer are smaller than internal crystal grains
Data Source
AI summary
An audio/video cable includes a plurality of parallel arranged insulated wires or twisted pair insulated wires each including a copper conductor and an insulation layer formed on a periphery thereof. The copper conductor includes a soft dilute copper alloy material containing pure copper, an additive element and an inevitable impurity as a balance. The soft dilute copper alloy material includes a recrystallized structure having a grain size distribution such that crystal grains in a surface layer are smaller than internal crystal grains. The surface layer includes a crystal structure such that an average crystal grain size from a surface of the surface layer up to a depth of 50 μm toward inside of the soft dilute copper alloy material is not more than 20 μm.