Multilayer Graphene Conductive Wire for Lower Weight at Equal Conductivity
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Solution Overview
Problem
Existing electric wires, including those with copper cores and single graphene layers, fail to significantly reduce the weight-to-conductivity ratio while maintaining conductivity and cost-effectiveness, particularly in applications like aeronautics, where lighter yet conductive alternatives to copper wires are needed.
Innovation Solution
A multilayer electrically conductive wire design featuring a central core surrounded by alternating layers of non-carbon intercalary materials and graphene layers, with each graphene layer separated by an intercalary layer, optimizing weight, conductivity, and manufacturing cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper wire is used to achieve high electrical conductivity, then electrical conductivity is improved, but weight increases
Solution Approach 1:
The patent uses a composite structure combining copper core with multiple graphene layers separated by intercalary layers. Graphene has superior electrical conductivity per unit weight compared to copper, and by stacking multiple graphene layers with appropriate spacing, the composite achieves high overall conductivity while significantly reducing weight (up to 61% weight reduction demonstrated).
Solution Approach 2:
The conductive material is segmented into multiple thin graphene layers separated by intercalary layers, rather than using a solid copper wire. This segmentation allows the lightweight graphene to provide the primary conductive function while the intercalary layers maintain proper spacing and structural integrity, achieving both weight reduction and conductivity preservation.
2Weight of moving object
If multiple graphene layers are added to reduce weight, then weight reduction is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process uses the copper core itself as a template for graphene deposition. The copper core's surface naturally guides the formation of graphene layers through chemical vapor deposition, and the intercalary layers are automatically positioned between graphene layers during the deposition process, reducing the need for complex external alignment and positioning systems.
Solution Approach 2:
The patent controls the thickness and number of graphene layers by adjusting deposition parameters such as deposition time, temperature, and gas flow rates during chemical vapor deposition. By optimizing these parameters, multiple uniform graphene layers can be deposited consistently, managing manufacturing complexity through parameter control rather than complex mechanical systems.
3Weight of moving object
If graphene layers are deposited on copper core, then weight reduction is achieved, but electrical conductivity gain is insufficient
Solution Approach 1:
Instead of adding a single thin graphene layer, the patent stacks multiple graphene layers in the radial dimension around the copper core. This multi-layer arrangement in the radial direction provides cumulative conductivity improvement that compensates for the removal of copper material, achieving both weight reduction and sufficient conductivity gain (maintaining around 0.288 ohms/m resistivity).
Solution Approach 2:
The patent creates a composite structure where multiple graphene layers work together with the copper core and intercalary layers to provide the required electrical conductivity. The synergistic combination of materials allows the system to achieve high conductivity with reduced weight, as graphene's superior conductivity per unit weight compensates for the reduced copper content.
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 multilayer design achieves a weight reduction of up to 61% compared to copper wires at equal conductivity, enhances mechanical strength, and improves thermal and electrical conductivity, making it suitable for aerospace applications.
Implementation Method 1
the fact of adding an intercalary layer made of a non-carbon material on a graphene layer makes it possible to physically insulate the graphene layers so that they each conserve their thickness and their optimal properties notably to maximise their conductivity
Implementation Method 2
the thermal conductivity of graphene (for example, that of a graphene monolayer obtained by CVD on copper is around 2500 W/m K) reinforces that of the intercalary metal
Implementation Method 3
a graphene layer, in which a gas comprising carbon is introduced and in which is deposited a graphene layer on the outer surface of the intercalary layer
Data Source
AI summary
A multilayer electrically conductive wire includes a central support core, and a set of pairs of layers each including at least one intercalary layer made of a non-carbon material, wherein the first layer of the first pair of layers is deposited on the outer surface of the central core and the first layer of the N+1 pair of layers is deposited on the second layer of the N pair of layers such that each graphene layer of each N pair is separated from another graphene layer of another pair of layers by an intercalary layer of another non-carbon based material.