Indium Copper Shield Cable for Repeated Bending Durability
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Solution Overview
Problem
Copper alloy wires used in shield layers of cables experience a decrease in shield performance when repeatedly bent or twisted, leading to potential breakage and loss of functionality.
Innovation Solution
A cable design incorporating a copper alloy wire with indium content between 0.3 and 0.65 mass % for the shield layer, combined with a braided structure and a sheath, which maintains high tensile strength and electrical conductivity, thereby resisting deformation-induced performance loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional copper alloy wires are used in shield layers, then the cable can be manufactured with standard materials, but the shield performance decreases when the cable is repeatedly bent or twisted
Solution Approach 1:
The patent changes the chemical composition parameters of the copper alloy by precisely controlling the indium content (0.03-0.65 mass%) and tin content (0.01-0.1 mass%), which fundamentally alters the material's mechanical properties to achieve both high strength and good ductility, resolving the contradiction between shield performance reliability and resistance to deformation during bending and twisting
Solution Approach 2:
The patent creates a composite copper alloy system by combining copper with specific amounts of indium and tin, where indium provides solid solution strengthening and tin contributes to precipitation hardening, forming a composite microstructure that simultaneously delivers high tensile strength (≥350 MPa) and adequate elongation (≥7%), thus maintaining shield performance under repeated mechanical stress
2Strength
If the copper alloy wire has high tensile strength to resist breakage, then the shield layer durability improves, but the elongation and flexibility may be reduced
Solution Approach 1:
The patent optimizes the alloy composition parameters within specific ranges (indium: 0.03-0.65 mass%, tin: 0.01-0.1 mass%) to achieve a balanced microstructure that provides both high tensile strength (≥350 MPa) and sufficient elongation (≥7%), ensuring the wire maintains flexibility while resisting breakage during cable installation and use
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 cable's shield performance remains intact even after extensive bending and twisting, with the copper alloy wire's high tensile strength and conductivity ensuring durability and reliability.
Implementation Method 1
a metallic wire made of a copper alloy wire made of a copper alloy containing indium, a content of which is equal to or more than 0.3 mass % and equal to or less than 0.65 mass %
Data Source
AI summary
A cable includes: a cable core including one or more electrical wires; a shield layer made of a metallic wire arranged on a periphery of the cable core; and a sheath arranged on a periphery of the shield layer. The metallic wire is made of a copper alloy wire made of a copper alloy containing indium, a content of which is equal to or more than 0.3 mass % and equal to or less than 0.65 mass %, and the metallic wire has tensile strength that is equal to or higher than 350 MPa and elongation that is equal to or higher than 7%.