Conductive Particle Cable Transverse Conductivity
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Solution Overview
Problem
Electrical cables with multiple conductors face reduced conductivity due to surface reactions and oxidation layers forming between conductors, which impede transverse conductivity.
Innovation Solution
Incorporating electrically conductive particles between the conductors, which are pressed into the conductor surfaces during winding, creating a mechanical and electrical connection that bypasses oxidation layers and enhances transverse conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are wound around each other in a cable, then the cable structure is formed and conductors are held in position, but oxidation layers form on the conductor surfaces which reduce transverse electrical conductivity
Solution Approach 1:
Electrically conductive particles are introduced as intermediary elements between the conductors. These particles serve as a conductive pathway that bridges the oxidation layers on conductor surfaces, allowing electrical current to flow through the particles rather than being blocked by the insulating oxidation layers. The particles are pressed into the conductor surfaces during winding, creating mechanical and electrical connections that bypass the harmful oxidation barriers.
2Reliability
If electrically conductive particles are arranged between conductors, then transverse electrical conductivity is improved, but the complexity of the cable structure increases
Solution Approach 1:
The conductive particles are integrated into the cable structure during the winding process itself, merging the particle application step with the conductor winding operation. The particles are fed onto the conductors and pressed into place by the winding action, combining multiple functions (particle placement, mechanical connection, and electrical pathway creation) into a single manufacturing process step, thereby reducing overall structural and process complexity.
3Reliability
If conductive particles are pressed into conductor surfaces during winding, then mechanical and electrical connection is achieved, but the winding process requires precise control
Solution Approach 1:
The winding process itself generates the necessary pressing force to embed the conductive particles into the conductor surfaces. As the conductors are wound around each other, the natural tension and compression forces during winding automatically press the particles into place, creating mechanical and electrical connections without requiring separate pressing equipment or additional process controls. The winding operation serves its primary function while simultaneously achieving particle embedding.
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 significantly improves transverse electrical conductivity by embedding conductive particles between the conductors, ensuring a stable and efficient connection that is not compromised by subsequent oxidation, while allowing for seamless winding and crimping processes.
Implementation Method 1
During the winding operation of the conductors, a transverse force is thereby applied to the particles, which are located between the conductors. The particles are thereby pressed into the surface of the conductors.
Implementation Method 2
owing to the particles, an electrically conductive transverse connection is produced between the conductors
Data Source
Figure 1~3
AI summary
The present invention comprises a cable (1) having at least two electrical conductors (3, 4) which are directly in abutment with each other, wherein the two conductors are surrounded by an electrically insulating cable sheath (2), characterised in that there are provided between the conductors electrically conductive particles (5) which produce an electrically conductive connection between the conductors.