Flat Twisted Wire Conductor Structure for High Flexibility

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Solution Overview

Problem

Conventional flat cable electric wire conductors, when formed into a highly flattened shape, experience decreased flexibility due to deformation of elemental wires at the inner side, leading to crowding and adhesion, which can result in material hardening and reduced flexibility.

Innovation Solution

The electric wire conductor is designed with a strand of sub-strands, where the sub-strands are composed of elemental wires twisted together, forming a flat shape with a higher number of outer elemental wires compared to inner elemental wires, maintaining a ratio of 2.0 or higher to ensure high flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the electric wire conductor is formed into a horizontally long and highly flat shape to reduce height and enhance space-saving properties, then the space-saving property is improved, but the flexibility of the electric wire conductor deteriorates due to deformation of inner elemental wires

Engineering Contradiction:

Improveheight occupied by electric wire conductorVSAvoidflexibility of electric wire conductor

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The patent applies local quality by creating different structural characteristics in different regions of the conductor. The inner sub-strands have fewer elemental wires (reducing deformation and hardening in the critical inner region), while outer sub-strands have more elemental wires (maintaining overall conductivity and structural integrity). This non-uniform distribution allows the conductor to be highly flattened for space-saving while preserving flexibility where it matters most.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs asymmetry by deliberately creating an asymmetric distribution of elemental wires across the conductor's cross-section. Instead of uniform distribution, the inner sub-strands contain fewer wires while outer sub-strands contain more wires. This asymmetric structure optimizes the balance between achieving high flatness (for space-saving) and maintaining flexibility (by reducing wire count in the highly stressed inner region).

Inventive Principle:

Principle #4Asymmetry

2Shape

If a strand is formed into a flat shape by applying force, then the flat outer shape is achieved, but the elemental wires at the inner side undergo greater deformation leading to crowding and adhesion

Engineering Contradiction:

Improveflat outer shape of strandVSAvoidarrangement of elemental wires

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies preliminary action by pre-arranging the elemental wires into sub-strands with specific wire counts before the flattening process. The inner sub-strands are pre-configured with fewer wires to anticipate and prevent the crowding and adhesion problems that would occur during flattening. This preliminary structural arrangement ensures that when force is applied to create the flat shape, the inner wires are already positioned to minimize deformation and maintain stable composition.

Inventive Principle:

Principle #10Preliminary action

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 configuration reduces deformation and crowding of inner elemental wires, maintaining flexibility even when the conductor is highly flattened, as the increased number of outer wires distributes load effectively and prevents material hardening.

Implementation Method 1

a plurality of sub-strands (2) including a plurality of elemental wires (3) twisted together

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250174373A1Electric wire conductor, insulated electric wire, and wiring harness

Publication Date: 2025.05.29 AUTONETWORKS TECH LTD

AI summary

Disclosed is to provide an electric wire conductor that includes a strand of elemental wires twisted together, the strand formed into a flat shape, which can ensure high flexibility, and also to provide an insulated electric wire and a wiring harness including such an electric wire conductor.An electric wire conductor 1 includes a strand comprising a plurality of sub-strands 2, the plurality of the sub-strands 2 including a plurality of elemental wires 3 twisted together, wherein, the strand comprises a flat portion having a flat outer shape in which a dimension in a width direction w is larger than a dimension in a height direction h, in a cross-section perpendicular to an axial direction of the strand, the plurality of the sub-strands 2 include outer sub-strands 2o and at least one of inner sub-strands 2i, the outer sub-strands 2o placed at an outer periphery of the flat portion, and the inner sub-strands 2i placed inside the outer sub-strands, a ratio of a number of outer elemental wires to a number of inner elemental wires is 2.0 or higher, where a total number of the elemental wires 3 composing the outer sub-strands 2o is defined as the number of the outer elemental wires, and a total number of the elemental wires 3 composing the inner sub-strands 2i is defined as the number of the inner elemental wires.