Copper Alloy Stranded Wire for Impact Resistance
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Solution Overview
Problem
There is a demand for electrical wires that are both conductive and strong, with excellent impact resistance, particularly for automotive and industrial applications where thin copper-based wires are prone to breaking under impact due to their small cross-sectional area and weight, and existing wires lack sufficient fatigue resistance and terminal fixation strength.
Innovation Solution
A covered electrical wire comprising a stranded conductor made of copper alloy wires with specific compositions of Fe, P, and Sn, which are work-hardened to enhance strength and conductivity, and feature an insulating covering layer to improve impact resistance and terminal attachment reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thin copper-based wires are used to reduce weight, then weight is reduced, but impact resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the copper alloy by precisely controlling the content ranges of Fe (0.01-1.5 mass%), P (0.01-0.5 mass%), and Sn (0.01-1.0 mass%), along with their mass ratios, to achieve enhanced mechanical properties while maintaining reduced weight. This compositional parameter optimization allows thin wires to achieve both weight reduction and improved impact resistance simultaneously.
Solution Approach 2:
The patent creates a composite copper alloy material by combining multiple elements (Cu-Fe-P-Sn) with specific compositional relationships. The synergistic interaction between these elements produces a composite alloy structure that delivers superior strength-to-weight ratio and impact resistance compared to pure copper or simpler alloys, resolving the contradiction between weight reduction and strength maintenance.
2Strength
If work hardening is applied to enhance strength, then strength is improved, but conductivity deteriorates
Solution Approach 1:
The patent optimizes the chemical composition parameters to balance work hardening effects with electrical conductivity. By controlling Fe content at 0.01-1.5 mass% and maintaining specific mass ratios (Fe/P≥2, Fe/Sn≥1), the alloy achieves adequate strength through work hardening while limiting conductivity degradation to acceptable levels, thus resolving the trade-off between strength enhancement and conductivity preservation.
3Reliability
If terminal fixation strength is improved through material composition, then terminal attachment reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent establishes specific compositional parameter ranges and ratios that directly improve terminal fixation strength through enhanced mechanical properties. While this requires precise compositional control during manufacturing, the defined ranges provide clear manufacturing guidelines that balance the need for improved terminal attachment reliability with practical manufacturability constraints.
Data Source
AI summary
A covered electrical wire comprises a conductor and an insulating covering layer provided outside the conductor, the conductor being a stranded wire composed of a strand of a plurality of copper alloy wires: composed of a copper alloy containing Fe in an amount of 0.2% by mass or more and 1.6% by mass or less, P in an amount of 0.05% by mass or more and 0.4% by mass or less, and Sn in an amount of 0.05% by mass or more and 0.7% by mass or less, with the balance being Cu and impurities, and having a mass ratio of Fe/P of 4.0 or more; and having a wire diameter of 0.5 mm or less.