Precipitation-Strengthened Copper Alloy Wire for Crimping
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Solution Overview
Problem
Electrical wires with a conductor cross-sectional area of 0.13 sq mm face challenges in achieving a terminal fixing load of 70 N or more due to limited crimping height range, making it difficult to substitute them for wires with larger areas, and adjusting crimping height is intricate, especially with annealed or hard copper alloys.
Innovation Solution
The use of a precipitation strengthened copper alloy with a cross-sectional area of 0.13 sq mm, providing a rate of elongation of 7% or more and a tensile strength of 500 MPa or more, broadening the crimping height range for achieving a terminal fixing load of 70 N or more, and maintaining electrical conductivity at 70% IACS or more, allowing for easier crimping and reduced strength decrease during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the conductor cross-sectional area is reduced to 0.13 sq mm for weight savings, then vehicle weight decreases, but the terminal fixing load cannot reach 70 N or more with conventional materials
Solution Approach 1:
The patent changes the material parameters by using precipitation strengthened copper alloy instead of conventional annealed copper or hard copper, achieving both high strength (500 MPa or more) and high elongation (7% or more) in a 0.13 sq mm conductor, enabling terminal fixing load of 70 N or more while maintaining weight savings
Solution Approach 2:
The patent employs a composite material approach by using precipitation strengthened copper alloy that combines copper base material with strengthening elements, creating a material that exhibits both high strength and high ductility properties that cannot be achieved with conventional single-phase copper materials
2Strength
If the crimping height is adjusted to achieve terminal fixing load of 70 N or more with 0.13 sq mm wire, then terminal fixing load is satisfied, but the crimping height range is very limited requiring high accuracy
Solution Approach 1:
The patent changes the material parameters by using precipitation strengthened copper alloy with specific tensile strength (500 MPa or more) and elongation (7% or more), which broadens the crimping height range and reduces the required manufacturing precision for achieving terminal fixing load of 70 N or more
3Strength
If hard copper or hard copper alloy is used to increase tensile strength, then tensile strength improves, but the crimping height range remains limited
Solution Approach 1:
The patent changes the material parameters by using precipitation strengthened copper alloy that achieves high tensile strength (500 MPa or more) while maintaining high elongation (7% or more), unlike hard copper or hard copper alloy which have limited elongation and narrow crimping height range
Solution Approach 2:
The patent employs a composite material approach by using precipitation strengthened copper alloy that combines copper base material with strengthening elements, creating a material that exhibits both high strength and high ductility properties that cannot be achieved with conventional hard copper materials
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
This solution enables the electrical wire to maintain a terminal fixing load of 70 N or more with a broader crimping height range, simplifying the adjustment process and ensuring the wire can be used as both a signal and power source line without significant strength reduction, addressing the limitations of annealed or hard copper alloys.
Implementation Method 1
tensile strength of 500 MPa or more is obtained by work strain (work hardening) to some extent
Data Source
AI summary
An electrical wire and an electrical wire with a terminal capable of diminishing the adjustment of a crimping height. There is provided an electrical wire 1 including a conductor part 11 that is made of a precipitation strengthened copper alloy having a cross-sectional area of 0.13 sq in the ISO 6722 standard and is compressed, wherein the conductor part 11 has a rate of elongation of 7% or more, and a tensile strength of 500 MPa or more. In addition, the electrical conductivity of the conductor part is 70% IACS or more.