Copper Alloy Inspection Wire With Twisted Fibrous Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conductive wires for electrical properties testing face challenges in achieving high hardness and high conductivity, particularly due to the decrease in conductivity during wire drawing or rolling processes, and the difficulty in producing wires with large casting diameters which increases production costs and reduces productivity.
Innovation Solution
A conductive wire composed of a copper alloy containing 0.1 to 30 mass% of silver, with a fibrous structure extending at an angle of 0.5° to 20.0° relative to the length direction, and produced through a twisting process that involves conveying and rotating the wire to achieve the desired structural orientation and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire drawing or rolling is used to increase hardness, then hardness increases, but conductivity decreases
Solution Approach 1:
The invention changes the processing parameters by using a specific twisting process with controlled angles (10-70 degrees) and rotation speeds (1-60 rotations/mm) instead of conventional wire drawing or rolling. This creates a fibrous structure that increases hardness while preserving conductivity better than traditional methods.
Solution Approach 2:
The invention uses a copper alloy composite material containing silver (0.1-30 mass%) combined with a specific fibrous structure created through twisting. The combination of the alloy composition and the twisted fibrous structure achieves both high hardness and high conductivity simultaneously.
2Ease of manufacture
If casting diameter is increased to enable wire drawing, then wire drawing becomes feasible, but productivity decreases and production costs increase
Solution Approach 1:
Instead of increasing casting diameter to enable wire drawing, the invention inverts the approach by using a twisting process that can be applied to smaller diameter wires. This eliminates the need for large casting diameters and the associated productivity losses.
Solution Approach 2:
The invention replaces the mechanical wire drawing or rolling system with a twisting system that rotates the wire during conveyance. This substitution allows processing of smaller diameter wires more efficiently, improving productivity while achieving the desired hardness.
3Strength
If multiple wire drawing or rolling processes are repeated, then hardness increases, but production time increases
Solution Approach 1:
The invention performs the hardness-enhancing action in advance through a single twisting process that creates the fibrous structure during wire formation. This preliminary action eliminates the need for repeated subsequent wire drawing or rolling operations, reducing production time.
Solution Approach 2:
The invention merges the hardness enhancement process with the wire formation process by implementing twisting during the conveying and forming stages. This combination achieves both wire fabrication and hardness improvement in a single integrated process, reducing total production time.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
An object of the present invention is to provide a conductive wire for electrical properties testing and having high hardness and high conductivity. A conductive wire for electrical properties testing that achieves the above object is composed of a copper alloy, and includes in its outer periphery portion a fibrous structure extending at an angle of 0.5 to 20 degrees with respect to the length direction of the conductive wire.