Braided Cord with Conductive Foil for Cost Reduction
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Solution Overview
Problem
Conventional shielded cords for leakage current detection and interruption (LCDI) applications require 85% copper braiding coverage, making them expensive due to rising copper costs, necessitating a more economical construction that reduces copper braiding while maintaining electrical conductivity.
Innovation Solution
A braided cord design featuring a conductive foil made of aluminum or copper wrapped around the hot and neutral wires, with a copper braid covering a reduced area, potentially as low as 5% to 10%, and an optional plastic backing, allowing for compliance with NEC and UL standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If 85% copper braiding coverage is used to meet UL standards, then electrical conductivity and safety are ensured, but manufacturing cost increases significantly due to rising copper prices
Solution Approach 1:
The patent applies composite materials by combining aluminum foil with copper braiding to create a hybrid shielding structure. The aluminum foil provides continuous coverage at lower cost, while the copper braid (at reduced 5-10% coverage) provides necessary conductivity and grounding capability, resolving the contradiction between meeting UL standards and reducing manufacturing costs
Solution Approach 2:
The patent changes the material parameter from 100% copper braiding to a composite of aluminum foil plus reduced copper braid coverage. This parameter change maintains the electrical conductivity required for LCDI applications while significantly reducing copper consumption and manufacturing cost
2Ease of manufacture
If copper braiding coverage is reduced to lower costs, then manufacturing becomes more economical, but electrical conductivity and safety standard compliance may be compromised
Solution Approach 1:
The aluminum foil acts as an intermediary between the reduced copper braid and the cable core. It provides continuous electrical contact along the cable length, mediating the electrical conductivity function that would otherwise require high copper braid coverage, thus enabling cost reduction while maintaining reliability
Solution Approach 2:
The aluminum foil performs multiple functions: it provides continuous electrical shielding, serves as a ground path, and reduces the required copper braid coverage. This multi-functionality allows the system to maintain reliability with reduced copper content, resolving the contradiction between cost and conductivity
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
This design significantly reduces manufacturing costs by minimizing copper braiding while ensuring electrical conductivity and safety standards compliance, making the cords more economical for LCDI applications, such as room air conditioner power supply cords.
Implementation Method 1
A braided cord utilizing a conductive foil made of aluminum or copper or any electrically conductive material
Data Source
AI summary
A braided cord having a conductive foil made of aluminum or copper or similar good electrically conductive materials. The foil is wrapped around the line (hot) and neutral wires of a cord. Over the foil is the braid made of copper strands.