Braided Copper-Clad Aluminum Conductor for Flexible Power Distribution
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Solution Overview
Problem
Existing power distribution systems face challenges in efficiently linking high-to-low voltage transformers to power distribution modules and transmitting low voltage power between electrical modules, often requiring multiple connections and compromising on flexibility and installation ease.
Innovation Solution
A low voltage power distribution system utilizing copper-clad aluminum wires braided into a power braid, secured by a clamp with a conductive clamp spacer that limits deformation, allowing for secure and flexible power transmission between electrical modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional power distribution systems use multiple connections to link transformers to power distribution modules, then reliability of power transmission is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent combines multiple separate connection points into a single integrated connection point. The power braid is designed with a unified structure that connects to the transformer housing at one location, eliminating the need for multiple separate connections while maintaining reliable power transmission through the integrated conductive path.
Solution Approach 2:
The single connection point serves multiple functions simultaneously: it provides electrical connection, mechanical support, and structural integration. The connection point is designed to handle both power transmission and physical mounting, reducing the overall complexity of the system.
2Strength
If rigid power conductors are used to ensure structural stability, then strength is improved, but flexibility and ease of installation deteriorate
Solution Approach 1:
The patent employs a power braid constructed from multiple flexible strands that can bend and conform to different installation paths. The braid structure provides flexibility while maintaining electrical conductivity, allowing easy installation in various configurations without requiring rigid support structures.
Solution Approach 2:
The power braid uses composite construction with multiple materials having different properties. The combination of conductive materials with flexible structural elements creates a conductor that simultaneously achieves both strength and flexibility, enabling both structural stability and ease of installation.
3Reliability
If copper wires are used to achieve high electrical conductivity, then electrical conductivity is improved, but weight increases
Solution Approach 1:
The patent uses copper-clad aluminum wires that combine the advantages of both materials. The aluminum core provides lightweight structure while the copper cladding ensures high electrical conductivity at the connection points. This composite approach achieves excellent electrical performance without the full weight penalty of solid copper conductors.
Solution Approach 2:
The high-conductivity copper material is applied locally only where electrical connection is critical (at the connection points and contact areas), while the bulk of the conductor uses lighter aluminum material. This localized application of premium material optimizes conductivity where needed while minimizing overall weight.
4Strength
If clamps apply high compression force to secure power braids, then mechanical retention is improved, but deformation of the power braid increases
Solution Approach 1:
The patent incorporates a clamp spacer that acts as a protective element between the clamp and the power braid. This spacer cushions the power braid against excessive compression forces, preventing deformation while still allowing the clamp to apply sufficient force for secure mechanical retention.
Solution Approach 2:
The clamp spacer serves as an intermediary element between the clamp mechanism and the power braid. It mediates the interaction by distributing the clamping force evenly and preventing concentrated stress points that would cause deformation, while maintaining adequate mechanical retention.
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 system enhances current-carrying capacity, reduces the number of connections needed, and facilitates quicker and easier installation by providing a flexible and lightweight power distribution solution with improved mechanical retention and electrical conductivity.
Implementation Method 1
a low voltage power conductor configured to supply power from a transformer to a power distribution module. The low voltage power conductor can include a plurality of copper-clad aluminum wires that may be braided into a power braid
Implementation Method 2
the at least two legs extending to opposing sides of the power braid to limit deformation of the power braid upon compression of the power braid by the clamp
Data Source
AI summary
A power conductor can include a plurality of copper-clad aluminum wires that are braided together to form a power braid. The power conductor can include an insulating sheath configured to enclose at least a portion of the power braid. The power conductor can be configured for use a power distribution system, and can be configured to electrically connect a transformer with a power distribution modules. The power conductor can be configured to connect to a conductive palm of the transformer and to a conductive contact of the power distribution module.