High-Frequency Electric Wire Compression for Diameter Reduction
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Solution Overview
Problem
Existing high-frequency electric wires face challenges in reducing outer diameter while preventing increased high-frequency resistance due to the skin effect and maintaining cost-effectiveness, particularly with the use of metal-pipe wire rods which hinder diameter reduction and lead to inefficiencies in signal transmission.
Innovation Solution
A high-frequency electric wire is manufactured by compressing multiple wire strands coated with a metal layer over an insulating resin wire rod, with a deformation ratio of 0-20% to minimize resistance and diameter, utilizing a sheath to encapsulate the conductor, thereby reducing waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a metal-pipe wire rod with a hollow portion is used to reduce costs by eliminating waste metal, then manufacturing costs are reduced, but the outer diameter of the electric wire cannot be reduced because a metal layer of approximately 10 μm thickness is required on the outside of a hollow portion with a diameter of 50 μm to transmit high-frequency signals equivalent to a wire strand with a diameter of 50 μm
Solution Approach 1:
The invention changes the material parameter of the core from metal (in traditional litz wire) or hollow (in metal-pipe wire rod) to insulating resin. This parameter change allows the wire rod to be fully insulating, enabling compression of the conductor without blocking hollow portions, thereby reducing the outer diameter while maintaining cost-effectiveness by eliminating the need for thick metal layers around hollow cores
Solution Approach 2:
The invention uses a composite structure where an insulating resin wire rod is coated with a metal layer to form a wire strand. This composite material approach allows the insulating core to provide structural support while the metal coating provides conductivity, enabling the wire to be compressed without blocking conductive paths, thus reducing outer diameter while maintaining electrical performance
2Length of stationary object
If the conductor is compressed to eliminate gaps between wire strands and reduce the outer diameter, then the outer diameter is reduced, but the hollow portion of the metal-pipe wire rod is blocked, preventing further compression
Solution Approach 1:
The invention changes the physical state of the wire rod from hollow (in metal-pipe wire rod) to solid insulating resin. This parameter change eliminates the blocking effect that prevents compression, allowing the conductor to be compressed to eliminate gaps between wire strands, thereby reducing the outer diameter while maintaining manufacturing feasibility
3Length of stationary object
If the deformation ratio of wire strands is increased beyond 20% to further reduce the outer diameter, then the outer diameter is reduced, but the metal layer cracks and high-frequency resistance increases
Solution Approach 1:
The invention optimizes the deformation ratio parameter to be within 0-20%, finding the optimal balance between diameter reduction and maintaining metal layer integrity. This parameter optimization ensures that the wire strands are compressed enough to reduce gaps and outer diameter, but not so much that the metal layer cracks and causes increased high-frequency resistance
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 approach effectively reduces the outer diameter of the high-frequency electric wire while maintaining low high-frequency resistance, preventing skin effect-induced increases and lowering production costs by utilizing resin for non-conductive areas, thus enhancing signal transmission efficiency.
Implementation Method 1
high-frequency signals are known to flow only through a vicinity of a surface of a conductor due to a skin effect during transmission of the high-frequency signals
Data Source
AI summary
A high-frequency electric wire is provided with a conductor which formed by compressing multiple wire strands, each of which is obtained by coating an outside of a wire rod made of insulating resin with a metal layer, and a sheath provided on the conductor. Each of the wire strands of the conductor is compressed in such a way that a deformation ratio of the wire strand exceeds 0% and is 20% or less. The compression is performed, for example, during bundling and sheathing of the multiple wire strands.