Copper Alloy Covered Wire Rigidity and Weld Strength
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Solution Overview
Problem
There is a demand for a covered electrical wire with a copper alloy conductor that maintains rigidity and impact resistance even with a small cross-sectional area, to prevent buckling when used in wire harnesses, and has low contact resistance and high weld strength, especially when used with terminal portions.
Innovation Solution
A covered electrical wire with a copper alloy conductor that is concentrically twisted from elemental wires containing Fe, Ti, Mg, Sn, Ag, Ni, In, Zn, Cr, Al, and P, with a low oil content on the surface, and an insulating coating layer, which reduces friction and enhances rigidity and weld strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the cross-sectional area of the conductor is reduced, then the weight of the wire is reduced, but the rigidity and impact resistance of the conductor deteriorate, causing buckling when terminal portions are inserted
Solution Approach 1:
The patent uses a copper alloy composite material containing specific elements (Fe: 0.01-2.0 mass%, Ti: 0.01-1.0 mass%, and at least one of Mg, Sn, Ag, Ni, In, Zn, Cr, Al, or P) to achieve both weight reduction and maintained rigidity. The alloy composition provides high strength-to-weight ratio while preventing buckling during terminal insertion
Solution Approach 2:
The patent optimizes the chemical composition parameters of the copper alloy and controls the oil adhering amount parameter (10 μg/g or less) to achieve the desired balance between weight and mechanical properties. By precisely controlling alloying element concentrations and surface oil content, the conductor achieves reduced weight without sacrificing rigidity
2Weight of moving object
If the cross-sectional area of the conductor is reduced, then the weight is reduced, but the weld strength when branch lines are welded deteriorates
Solution Approach 1:
The copper alloy composite with specific element composition (Fe, Ti, Mg, Sn, Ag, Ni, In, Zn, Cr, Al, P) provides enhanced weld strength despite reduced cross-sectional area. The alloying elements create a microstructure that maintains strong metallurgical bonds during welding operations
Solution Approach 2:
The patent controls the chemical composition parameters and surface oil content (10 μg/g or less) to optimize weldability. The reduced oil adhering amount prevents contamination during welding, while the alloy composition ensures strong joint formation even in small-gauge wires
3Ease of manufacture
If oil adhering to the surface of the central elemental wire is not controlled, then the ease of manufacture is improved, but the contact resistance increases and weld strength decreases
Solution Approach 1:
The patent establishes a specific parameter range for oil adhering amount (10 μg/g or less) that balances manufacturing ease with electrical and mechanical performance. This parameter control ensures low contact resistance and high weld strength while remaining practically manufacturable
Solution Approach 2:
The patent replicates the successful oil control parameter from larger gauge wires to small gauge wires, applying the same adhering amount threshold (10 μg/g or less) across different wire sizes to ensure consistent performance in contact resistance and weldability
Data Source
AI summary
A covered electrical wire including a conductor and an insulating coating layer covering an outer periphery of the conductor, in which the conductor is a twisted wire obtained by concentrically twisting together a plurality of elemental wires constituted by a copper alloy, the copper alloy contains one or more elements selected from Fe, Ti, Mg, Sn, Ag, Ni, In, Zn, Cr, Al, and P in a total amount of 0.01 mass % to 5.5 mass % inclusive, and the remaining portion includes Cu and inevitable impurities, and an amount of oil adhering to a surface of a central elemental wire disposed at a central portion of the twisted wire is 10 μg/g or less with respect to the mass of the central elemental wire.