Composite Flat Electric Wire for Shape Retention and Flexibility
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Solution Overview
Problem
Existing flat electric wires either prioritize shape retention or flexibility, but not both, leading to limitations in their application based on specific requirements.
Innovation Solution
A flat electric wire design comprising a combination of stranded wires made of a first metal and a solid wire made of a second metal with lower yield point, covered by an insulator with a specific Young's modulus, ensuring both shape retention and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the conductor is formed of a busbar, then the flat electric wire has excellent shape retention performance, but poor flexibility
Solution Approach 1:
The conductor is divided into multiple individual wires (first conductive member) that are stranded together to form a bundled structure. This segmentation allows the conductor to bend and flex more easily while maintaining overall shape retention, resolving the contradiction between rigidity and flexibility.
Solution Approach 2:
The conductor uses a composite structure combining multiple metal wires (different materials or treatments) within the same conductor bundle. This composite approach enables the conductor to exhibit both shape retention properties and flexibility by leveraging the characteristics of different metal components.
2Ease of operation
If the conductor is formed of a plurality of stranded wires, then the flat electric wire has excellent flexibility, but poor shape retention performance
Solution Approach 1:
The insulator is designed with different local properties: a first region with higher elasticity modulus providing shape retention, and a second region with lower elasticity modulus providing flexibility. This local differentiation allows the insulator to simultaneously achieve both shape retention and flexibility without compromising either property.
Solution Approach 2:
The insulator's elasticity modulus is varied across different regions to achieve different functional characteristics. By changing the physical parameter (elasticity modulus) of the insulator material in different zones, the patent achieves both shape retention and flexibility in the same component.
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 design achieves both shape retention and flexibility, maintaining the bent shape while minimizing electrical resistance and reducing distortion, with the solid wire's plastic deformation enhancing flexibility.
Implementation Method 1
a solid wire made of a second metal that has a lower yield point than the first metal
Implementation Method 2
an insulator configured to collectively cover the plurality of conductor portions
Data Source
AI summary
A flat electric wire includes a plurality of conductor portions that are arranged in parallel and that are in contact with each other, and an insulator configured to collectively cover the plurality of conductor portions. The plurality of conductor portions include a stranded wire that is formed by stranding wires made of a first metal, and a solid wire made of a second metal that has a lower yield point than the first metal.