Copper Alloy Stranded Wire Composition for Thin, Break-Resistant Cables
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Solution Overview
Problem
There is a demand for electrical wires that excel in conductivity, strength, and impact resistance, particularly for thin copper alloy wires used in automotive and industrial applications, where weight reduction is desired while maintaining mechanical integrity and productivity during manufacturing.
Innovation Solution
A covered electrical wire comprising a stranded copper alloy wire with a specific composition of Fe, P, and additional elements like Ni, Al, Cr, and Co, which is subjected to wire-drawing and heat treatment to enhance strength and impact resistance, and includes a method for manufacturing that suppresses segregation of P to improve plastic workability and reduce breakage during wire drawing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thin copper alloy wire is used to reduce weight, then weight reduction is achieved, but impact resistance and mechanical integrity deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the copper alloy by precisely controlling the content ranges of Fe (0.1-1.6%), P (0.05-0.7%), and other elements (Ni, Al, Cr, Co). This composition optimization enables thin wires to achieve both light weight and high impact resistance simultaneously, resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The patent creates a composite copper alloy material by combining multiple elements (Cu-Fe-P-Ni/Al/Cr/Co) to achieve synergistic effects. The Fe and P form precipitates that strengthen the matrix, while the additional elements enhance specific properties, resulting in a composite material that maintains high strength and impact resistance at reduced wire diameter.
2Weight of moving object
If wire diameter is reduced to 0.5mm or less for weight reduction, then weight decreases, but susceptibility to breakage during manufacturing increases
Solution Approach 1:
The patent optimizes compositional parameters (Fe: 0.1-1.6%, P: 0.05-0.7%) to enhance the material's inherent toughness and ductility. This enables thin wires (0.5mm or less) to maintain sufficient breakage resistance during manufacturing processes while achieving weight reduction goals.
Solution Approach 2:
The patent applies preliminary heat treatment to the copper alloy wire before final manufacturing processes. This preliminary action pre-establishes the microstructure and mechanical properties, ensuring that the thin wire has adequate breakage resistance from the outset, preventing manufacturing failures.
3Strength
If copper alloy composition is optimized for strength, then impact resistance improves, but manufacturing complexity increases
Solution Approach 1:
The patent defines specific parameter ranges for each alloying element (Fe: 0.1-1.6%, P: 0.05-0.7%, Ni/Al/Cr/Co: 0.01-0.7%) that balance strength enhancement with manufacturing feasibility. These controlled parameter changes achieve high impact resistance while maintaining manageable composition complexity through clear specification of acceptable ranges.
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 provides electrical wires with high conductivity, strength, and impact resistance, along with improved productivity by preventing breakage during wire drawing, making them suitable for automotive and industrial applications.
Implementation Method 1
subjecting the wire-drawn member to heat treatment
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 plurality of copper alloy wires composed of a copper alloy and twisted together, and having a wire diameter of 0.5 mm or less, the copper alloy containing Fe in an amount of 0.1% by mass or more and 1.6% by mass or less, P in an amount of 0.05% by mass or more and 0.7% by mass or less, and one or more elements selected from Ni, Al, Cr and Co in an amount of 0.01% by mass or more and 0.7% by mass or less in total, with a balance being Cu and impurities.