Grounding Cable with Composite Wires and Mesh
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Solution Overview
Problem
Traditional vehicle electrical systems suffer from poor electrical conductive efficiency, leading to ineffective operation of electrical load components and reduced overall vehicle performance.
Innovation Solution
A grounding conductive cable structure comprising a cable main body with twisted copper and silver-plated wires, oxygen-free copper wires, and a woven mesh layer, along with gold-plated conductive terminals and tin-silver solder layers, to enhance electrical conductivity and reduce impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional vehicle electrical systems use conventional cable structures, then the system is simple and easy to manufacture, but the electrical conductive efficiency is poor
Solution Approach 1:
The cable employs a composite wire structure combining copper wires (high conductivity) and silver-plated wires (oxidation resistance) twisted together in bundles. This composite material approach achieves both high electrical conductive efficiency and oxidation resistance, directly resolving the technical contradiction between reliability and structural complexity.
Solution Approach 2:
The cable main body is divided into multiple main-wire bundles and subsidiary-wire bundles, each containing multiple twisted wires. This segmentation allows for optimized electrical performance through increased surface area and improved current distribution, while maintaining manageable structural complexity through modular organization.
2Reliability
If the cable uses more copper wires and silver-plated wires to improve conductivity, then the electrical conductive efficiency increases, but the manufacturing complexity and cost increase
Solution Approach 1:
The cable divides wires into multiple small bundles (main-wire bundles and subsidiary-wire bundles) rather than using a single large conductor. This segmentation achieves high electrical conductive efficiency through increased total surface area and current distribution, while keeping manufacturing complexity manageable through standardized bundle structures that can be produced and assembled systematically.
Solution Approach 2:
The combination of copper and silver-plated wires in specific ratios (5000-20000 total wires) creates a composite structure that optimizes electrical performance. The copper provides bulk conductivity while silver-plated wires provide oxidation resistance at contact points, achieving high efficiency without requiring excessive material quantities that would complicate manufacturing.
3Ease of manufacture
If the cable structure is simplified for ease of manufacture, then manufacturing is easier, but the electrical conductive efficiency decreases
Solution Approach 1:
The cable uses standardized bundle structures with copper wires and silver-plated wires twisted together in regular patterns. This segmentation into manageable units maintains manufacturing simplicity through repetitive, modular assembly processes, while simultaneously achieving high electrical conductive efficiency through the cumulative effect of multiple conductive pathways and increased surface area.
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 improves power usage efficiency, stabilizes ground potential, reduces electrical noise, and increases engine performance and fuel efficiency by effectively transmitting large quantities of electrical current with minimal inductance and capacitance.
Implementation Method 1
Each of the main-wire bundles includes copper wires and silver-plated wires which are twisted in bundles together. The total number of the copper wires and the silver-plated wires is 5,000 to 20,000
Implementation Method 2
The conductive terminals are respectively coupled to two opposite ends of the cable main body with soldering, and electrically connected to the main-wire bundles and the subsidiary-wire bundles. Two tin-silver solder layers are connected each of the two conductive terminals and one of the two opposite ends of the cable main body
Data Source
AI summary
A grounding conductive cable structure includes a cable main body, two conductive terminals and a woven mesh layer. The cable main body includes copper wires, silver plated wires, silver wires and oxygen-free copper wires. The total number of these copper wires and the silver plated copper wires is 5,000 to 20,000, and the number of the copper wires is greater than the number of the silver plated copper wires. The conductive terminals are electrically connected to the two opposite ends of the cable main body and electrically connected to those wires. The cable main body is wrapped by the woven mesh layer.