Compressed Stranded Wire Conductor for Thin Flexible Signal Cables
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Solution Overview
Problem
Existing thin conductors with diameters of 0.1 mm or less are prone to breakage during bending or twisting due to poor electrical characteristics and manufacturing difficulties, and conventional stranded conductors compromise electrical performance.
Innovation Solution
A compressed stranded wire conductor with a central portion and surrounding portions spirally twisted together, coated with a second metal part of higher conductivity, enhancing electrical characteristics and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single (solid) wire conductor with thin diameter is used, then good electrical characteristics are achieved, but it is easily broken when subjected to bending or twisting
Solution Approach 1:
The conductor is divided into multiple thin metal strands (7 strands in the embodiment) that are twisted together to form a stranded conductor. This segmentation allows the conductor to flex and bend without breaking individual wires, improving mechanical strength while maintaining electrical performance through the twisted structure that ensures continuous contact between strands.
Solution Approach 2:
The invention uses a composite structure combining multiple metal strands with different materials or treatments. The stranded configuration creates a composite conductor that leverages the strengths of individual strands while distributing mechanical stress, preventing breakage during bending and twisting operations.
2Strength
If a stranded conductor made by twisting multiple metal strands is used to increase resistance to bending, then mechanical strength is improved, but electrical characteristics deteriorate due to small contact areas between metal strands
Solution Approach 1:
The invention optimizes parameters including the number of strands (7 strands), the twisting pitch, and strand diameter ratios to maximize contact area between strands. By carefully controlling these parameters, the conductor achieves both good mechanical flexibility and electrical conductivity, resolving the trade-off between strength and electrical characteristics.
3Reliability
If the outer diameter of the conductor is increased to secure desired conductor cross-sectional area in stranded conductors, then electrical characteristics are improved, but the outer diameter becomes larger than desired
Solution Approach 1:
By segmenting the conductor into multiple thin strands twisted together, the invention achieves the required cross-sectional area through the combined area of all strands while maintaining a compact outer diameter. The twisted structure allows efficient packing of strands, maximizing the use of internal space and minimizing the overall conductor diameter.
Solution Approach 2:
The invention transitions from a single-dimension solid wire to a three-dimensional twisted stranded structure. This dimensional change allows the conductor to achieve the required cross-sectional area through spatial arrangement of multiple strands in a twisted configuration, optimizing both the cross-sectional area and outer diameter simultaneously.
4Reliability
If a compressed stranded wire conductor is used to increase contact areas between metal strands, then electrical characteristics are improved, but it is difficult to manufacture with outer diameter of 0.1 mm or less because metal strands are prone to breakage during compression
Solution Approach 1:
The compression process is carefully controlled and optimized before final conductor formation. By applying preliminary compression at controlled stages during manufacturing, the strands are compacted to increase contact area while maintaining structural integrity. The manufacturing process is designed to apply compression gradually and uniformly, preventing breakage of thin strands during the compression stage.
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 conductor achieves improved electrical performance and resistance to breakage, facilitating manufacturing and enabling high-frequency signal transmission with reduced diameter.
Implementation Method 1
a second metal part made of a metal having a higher conductivity than the first metal part and covering each of the central portion and the plurality of surrounding portions
Implementation Method 2
a plurality of surrounding portions spirally twisted around the central portion
Data Source
AI summary
A compressed stranded wire conductor includes an outer diameter of 0.1 mm or less, a central portion, a plurality of surrounding portions spirally twisted around the central portion, a first metal part in which the central portion and the plurality of surrounding portions are fitted together to form a circular cross-section as a whole, and a second metal part made of a metal having higher conductivity than the first metal part and covering each of the central portion and the plurality of surrounding portions, wherein the central portion, the plurality of the surrounding portions, and adjacent ones of the surrounding portions, are attached together with the second metal part in between.