Non-metallic Light Conductive Wire with CNT Layer
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Solution Overview
Problem
Current methods for synthesizing carbon nanotube fibers, such as wet spinning, carbon nanotube array direct spinning, and floating chemical vapor deposition, face challenges including high costs, limited scalability, and poor electrical properties due to uneven nanotube walls and impurities.
Innovation Solution
A non-metallic light conductive wire is developed using a bundle of branch conductor wires with a high strength polymer fiber core wrapped in a carbon nanotube conductive layer and an insulating protective layer, allowing for large-scale industrial production with improved electrical and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet spinning method is used to synthesize carbon nanotube fiber, then mechanical properties and electrical properties are excellent, but production cost is too high
Solution Approach 1:
The patent replaces expensive double-wall carbon nanotubes (produced by costly wet spinning) with single-wall carbon nanotubes that can be produced more economically through chemical vapor deposition, achieving comparable electrical properties at lower cost
Solution Approach 2:
The patent changes the structural parameter from double-wall to single-wall carbon nanotubes, and optimizes the arrangement into bundled fascicular structures, achieving cost-effective electrical conductivity comparable to copper
2Reliability
If carbon nanotube array direct spinning method is used, then conductivity approaches copper, but scalability is limited by silicon substrate size
Solution Approach 1:
The patent divides the carbon nanotube structure into bundled fascicular units (multiple bundles per fiber, multiple fibers per strand), enabling modular scaling from laboratory to industrial production while maintaining high conductivity
Solution Approach 2:
The patent transitions from two-dimensional array structures to three-dimensional bundled fascicular structures, allowing scalable production independent of substrate size constraints
3Length of moving object
If floating chemical vapor deposition drawing method is used, then fiber length can reach several kilometers, but electrical properties are poor due to uneven nanotube walls and impurities
Solution Approach 1:
The patent performs purification of carbon nanotubes before fiber formation, removing catalyst particles and amorphous carbon impurities in advance to ensure high electrical conductivity in the final product
Solution Approach 2:
The patent changes from floating CVD to atmospheric pressure CVD method, and optimizes synthesis parameters to produce uniform single-wall nanotubes with consistent structure along the entire fiber length
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 solution enables cost-effective, scalable production of high-strength, lightweight conductive wires with enhanced electrical properties, suitable for applications like cables and motors, reducing equipment weight and improving performance.
Implementation Method 1
a carbon nanotube conductive layer wrapped on the core
Data Source
AI summary
The present invention relates to a non-metallic light conductive wire, a composite conductive wire, a special cable, a motor and the like application products made of the conductive wire, and a method of making the composite conductive wire.