Grooved High-Frequency Electric Wire Design
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Solution Overview
Problem
Existing electric wires face high electrical losses and resistance increases at high temperatures due to the skin effect, leading to increased power consumption in electric vehicles and inductive power supply systems, and are not suitable for high-frequency, high-voltage currents due to their size and weight constraints.
Innovation Solution
The electric wire design features a conductive wire with grooves along its longitudinal direction, where additional conductive wires are inserted to increase surface area and reduce resistance, using materials like copper and aluminum to enhance conductivity and flexibility, and an insulator sheath for improved insulation and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional conducting wires are used for high-frequency current, then the structure is simple, but the effective resistance increases due to skin effect and electric power loss increases
Solution Approach 1:
The wire is divided into multiple strands (e.g., 7 strands) instead of using a single solid conductor. This segmentation increases the effective surface area for current flow, reducing the impact of skin effect and lowering effective resistance and power loss.
Solution Approach 2:
Additional wires are inserted into grooves formed on the outer surface of the conductive wire. This nested structure increases the effective surface area without significantly increasing the overall wire diameter, effectively reducing skin effect while maintaining compact dimensions.
2Loss of energy
If litz wire is used to reduce skin effect loss, then electric power loss decreases, but the wire crumples when wound into coils making size and shape inconsistent
Solution Approach 1:
The wire structure incorporates a flexible outer sheath that maintains the geometric shape of individual strands. This allows the wire to be wound into coils without crumpling, ensuring consistent size and shape while maintaining the multi-strand structure needed to reduce skin effect loss.
3Loss of energy
If litz wire with small diameter strands is used, then surface area increases reducing skin effect, but the wire cannot handle high-voltage large current
Solution Approach 1:
The wire combines multiple functions in a unified structure: the conductive wire provides current carrying capacity for high-power applications, while additional wires inserted into grooves increase surface area to reduce skin effect loss. This merged structure simultaneously achieves both high current capacity and reduced power loss.
4Power
If wire diameter is increased to handle high-voltage large current, then current carrying capacity increases, but the size and weight of motors increase
Solution Approach 1:
Additional wires are nested into grooves on the conductive wire surface, effectively increasing the current-carrying cross-section without proportionally increasing the overall wire diameter. This allows high current capacity while maintaining compact motor size and reduced weight.
5Loss of energy
If grooves are added to increase surface area, then skin effect loss is reduced, but resistance still increases significantly at high temperatures
Solution Approach 1:
The wire uses composite material construction with copper core providing excellent conductivity and aluminum additional wires providing thermal stability. This composite structure reduces skin effect loss while the aluminum component helps maintain lower resistance increase at high temperatures compared to traditional single-material wires.
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 design reduces electrical power loss and maintains efficient high-frequency and high-voltage current transmission, allowing for compact, lightweight motors and consistent charging performance across various loads without the need for multiple chargers, while minimizing resistance increase at elevated temperatures.
Implementation Method 1
the current gathers around a surface of the conducting wire due to the skin effect. Therefore, the effective resistance of the conducting wire increases
Implementation Method 2
electric wire containing a conductive wire and an additional wire. The additional wire is inserted in the conductive wire along a longitudinal direction of the conductive wire
Implementation Method 3
The insulator is placed along a longitudinal direction of the conductive wire at a corner of the quadrilateral
Data Source
AI summary
An electric wire contains a conductive wire having at least a groove structured on the surface of the conductive wire, and an additional wire to be filled into the groove. The groove is provided on an outer surface of the conductive wire along a longitudinal direction of the conductive wire. The additional wire is inserted in the groove.