Copper-Clad Aluminum Coaxial Cable for Automotive Weight Reduction
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Solution Overview
Problem
Existing coaxial cables face high production costs due to solid copper usage, and alternatives like aluminum cables suffer from low conductivity, oxidation issues, and mechanical weaknesses, making them unsuitable for dynamic sectors like the automotive industry.
Innovation Solution
A coaxial cable design featuring a central conductive unit and bonding jumper made from copper-clad aluminum (CCA) wires with a tin coating, providing improved mechanical performance, oxidation resistance, and weldability, while maintaining low weight and cost through a specific wire structure and coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid copper is used for central conductive wire and bonding jumper, then electrical conductivity and signal transmission performance are improved, but production cost and material price volatility increase
Solution Approach 1:
The patent applies composite materials by combining copper coating (for conductivity) with aluminum core (for cost-effectiveness and weight reduction). The copper-clad aluminum structure provides both electrical conductivity through the copper layer and cost/weight benefits through the aluminum core, resolving the contradiction between performance and manufacturing cost.
Solution Approach 2:
The patent applies local quality by providing copper coating only on the surface layer where electrical contact occurs, while the inner core uses aluminum. This localized application of different material properties optimizes both conductivity (at the contact surface) and cost/weight (in the bulk material).
2Ease of manufacture
If pure aluminum is used for central conductive wire and bonding jumper, then production cost and weight are reduced, but electrical conductivity and oxidation resistance worsen
Solution Approach 1:
The copper-clad aluminum composite structure resolves this contradiction by using aluminum for the core (providing cost and weight benefits) while adding a copper coating layer (providing superior electrical conductivity and oxidation resistance). This composite approach combines the advantages of both materials.
Solution Approach 2:
The copper coating is applied locally on the aluminum core surface, providing enhanced conductivity and oxidation resistance only where needed for electrical contact, while the bulk aluminum core maintains cost and weight advantages.
3Ease of manufacture
If CCA wires are used for central conductive unit and bonding jumper, then production cost and weight are reduced, but oxidation resistance and weldability worsen
Solution Approach 1:
The patent uses a tri-layer composite structure: aluminum core (cost and weight benefits), copper intermediate layer (conductivity), and tin outer coating (oxidation resistance and weldability). This multi-material composite resolves all individual material limitations.
Solution Approach 2:
Different material layers are applied locally to address specific requirements: copper provides conductivity at the interface, while tin provides oxidation protection and weldability at the external surface exposed to environment.
4Object-affected harmful factors
If anti-oxidation substances are applied to CCA wires, then oxidation resistance and product shelf life are improved, but electrical conductivity and weldability decrease
Solution Approach 1:
The patent uses a multi-layer composite where tin coating provides oxidation resistance without significantly impacting electrical conductivity, unlike generic anti-oxidation substances. The tin layer maintains weldability and electrical properties while protecting against oxidation.
Solution Approach 2:
The tin coating is applied as a thin external layer that provides oxidation protection where needed (at the surface) while minimizing impact on bulk electrical conductivity and maintaining weldability characteristics.
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 offers a cost-effective, mechanically robust coaxial cable with stable electrical performance and corrosion resistance, suitable for dynamic applications like the automotive sector, with reduced weight and production costs compared to pure copper cables.
Implementation Method 1
The central conductive unit and the bonding jumper made with copper clad aluminum (CCA) technology and comprising an aluminum core and a copper coating
Implementation Method 2
copper has a high conductivity, and therefore a low electrical resistance and a low Ohmic loss
Implementation Method 3
The tin external layer (13) is used to make the conductive wire immune from oxidation and keep its weldability characteristics unaltered over time
Implementation Method 4
a dielectric material disposed between the central conductive unit and the shield to insulate the central conductive unit from the shield
Data Source
AI summary
A coaxial cable (100) comprising. a central conductive unit (1) intended to transport a signal, a shield (4) comprising a plurality of wires (40) disposed as a mesh, adapted to be connected to a mass to shield the central conductive unit, a dielectric material (2) disposed between the central conductive unit (1) and the shield (4) to insulate the central conductive unit (1) from the shield (4), and an insulating sheath (5) disposed around the shield (4), wherein said central conductive unit (1) and said shield (4) comprise a plurality of wires (10, 40) made of an aluminum core (11, 41) coated with a copper coating (12, 42), and said wires (40) of the shield (4) comprise a tin external coating (43).