Composite Conductor with Whisker-Infiltrated CNT Yarn
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Solution Overview
Problem
Carbon nanotube yarns used in electrical conductors face issues such as splitting, unfolding, and non-uniform mechanical and electrical performance due to impurities and fraying, which complicates termination and makes them susceptible to environmental degradation.
Innovation Solution
A composite conductor is developed with an elongate metallic support coated with whisker-forming materials like tin, indium, or their combinations, intertwined with carbon nanotube yarns, where self-assembled whiskers infiltrate the yarn to enhance mechanical and electrical uniformity, solderability, and resistance to unfolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If carbon nanotube yarns are used as electrical conductors to achieve weight reduction, then the conductor weight is reduced, but the yarns are susceptible to splitting, unfolding, and environmental degradation
Solution Approach 1:
The patent combines carbon nanotube yarns with a metallic core to form a composite conductor structure. The CNT yarn provides lightweight conductivity while the metallic core provides structural support and resistance to splitting and unfolding. This composite approach allows weight reduction while maintaining reliability.
Solution Approach 2:
The metallic core acts as an intermediary that prevents direct environmental exposure to the CNT yarns. By positioning the metallic core at the center, it serves as a barrier against environmental degradation while still allowing the CNT yarns to function as electrical conductors.
2Weight of moving object
If carbon nanotube yarns are used as electrical conductors to achieve weight reduction, then the conductor weight is reduced, but the yarns are susceptible to corrosion and thermal degradation from environmental effects
Solution Approach 1:
The metallic core serves as an intermediary barrier between the CNT yarns and the external environment. It protects the yarns from corrosive substances and thermal degradation by preventing direct contact with environmental factors while maintaining electrical conductivity.
Solution Approach 2:
The composite structure combines the lightweight, high-conductivity CNT yarns with a corrosion-resistant metallic core. This allows the conductor to maintain weight advantages while the metallic component provides protection against environmental harmful factors.
3Weight of moving object
If traditional copper wire is replaced with carbon nanotube yarns to achieve weight reduction, then the conductor weight is reduced, but the yarns exhibit non-uniform mechanical and electrical performance due to impurities
Solution Approach 1:
The composite structure with metallic core and CNT yarn shell allows the metallic core to provide uniform mechanical support and electrical conductivity, compensating for the non-uniformity of the CNT yarns. The core ensures consistent performance while the yarn provides weight reduction.
Solution Approach 2:
The metallic core provides a homogeneous, uniform structure that ensures consistent mechanical and electrical performance throughout the conductor. This uniformity compensates for variations in the CNT yarn layer, achieving overall homogeneity in the composite conductor.
4Weight of moving object
If carbon nanotube yarns are used as electrical conductors to achieve weight reduction, then the conductor weight is reduced, but the yarns have difficulty being inserted into terminals due to fraying
Solution Approach 1:
The composite structure with metallic core provides a solid, fray-resistant structure that is easy to terminate and insert into terminals. The metallic core maintains its shape and does not fray, while the CNT yarn layer provides lightweight conductivity.
Solution Approach 2:
The metallic core acts as an intermediary that provides a solid, manageable structure for termination operations. It serves as the primary interface for insertion into terminals, eliminating the fraying problems associated with pure CNT yarns while maintaining the weight advantages.
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 a lightweight conductor with improved conductivity, uniform performance, ease of termination, and resistance to mechanical stress, while the metallic support aids in preventing crushing and corrosion, and whisker infiltration provides additional conductive paths and anchoring points for solder adhesion.
Implementation Method 1
The yarn is infiltrated by self-assembled whiskers from the whisker forming metallic
Data Source
AI summary
A composite conductor is disclosed having an elongate support with an outer surface of a whisker-forming metallic, the conductor further having a carbon nanotube yarn intertwined with the elongate support. The yarn is infiltrated by self-assembled whiskers from the whisker forming metallic.