Copper-Coated Magnesium Wire for Lightweight High-Strength Coils
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Solution Overview
Problem
Copper-coated aluminum wires have low tensile strength, making them prone to breakage during coil winding, which complicates the process and reduces yield, and they are not suitable for miniaturization due to their weight and susceptibility to cracking.
Innovation Solution
A copper-coated magnesium wire with a magnesium core and a copper or copper alloy coating, allowing for cold drawing to a smaller diameter using regular equipment, thereby achieving a lightweight and high-strength coil wire material suitable for miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If copper-coated aluminum wire is used to reduce weight, then weight is reduced, but tensile strength becomes insufficient causing breakage during coil winding
Solution Approach 1:
The invention uses a composite wire structure with aluminum core and copper cladding. Aluminum provides weight reduction (specific gravity 2.7 vs copper's 8.96), while copper provides tensile strength and solderability. This composite structure resolves the contradiction by combining materials with complementary properties to achieve both weight reduction and sufficient mechanical strength.
Solution Approach 2:
The wire structure applies local quality by having different materials serve different functions: the aluminum core handles weight reduction requirements, while the copper outer layer handles tensile strength and surface quality requirements. This spatial differentiation of material properties allows the wire to meet multiple conflicting requirements simultaneously.
2Weight of moving object
If copper-coated aluminum wire is used, then weight is reduced, but the wire is susceptible to cracking and exposure during coil winding
Solution Approach 1:
The copper-clad aluminum composite structure provides both weight reduction and improved reliability. The copper outer layer protects the aluminum core from oxidation and cracking, while the aluminum core provides weight reduction. This composite structure resolves the contradiction between weight reduction and resistance to cracking during coil winding.
3Volume of moving object
If wire diameter is reduced for miniaturization, then coil size is reduced, but copper-coated aluminum wire lacks sufficient strength and requires dedicated equipment
Solution Approach 1:
The copper-clad aluminum wire maintains sufficient tensile strength even at reduced diameters for miniaturization applications. The copper outer layer provides the necessary strength-to-weight ratio, allowing the wire to be drawn through conventional equipment without requiring specialized processing equipment, thus resolving the contradiction between miniaturization and manufacturing ease.
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 copper-coated magnesium wire provides a lightweight and high-strength coil wire material that can be cold-drawn to a smaller diameter without the need for dedicated equipment, improving yield and reducing complications in coil winding, while maintaining conductivity and corrosion resistance.
Implementation Method 1
forming a matte copper plating layer as the copper plating layer by electrolytic copper plating on an outer circumference of a zinc thin film
Data Source
AI summary
To provide a copper-coated magnesium wire which meets the demand for a lightweight coil wire material, and a method for manufacturing the same. The above-described problem is solved by a copper-coated magnesium wire (10) comprising a core material (1) made of magnesium, and a copper coating layer (2) made of copper or a copper alloy provided on a surface of the core material (1). In the copper-coated magnesium wire (10), a wire drawing mark is present on a surface of the copper coating layer (2), and the diameter is preferably within a range of 0.03 to 0.08 mm, inclusive. Further, a thickness of the copper coating layer (2) is preferably within a range of 5 to 30%, inclusive, as a ratio of the overall cross-sectional area. An insulating coating layer (3) may be provided on an outer circumferential side of the copper coating layer (2).