Multi-Strand Conductor with Polymer-Filled Segments
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Solution Overview
Problem
Multi-strand electrical conductors have reduced conductor material per cross-sectional area due to interstitial space, which also allows fluid flow and increases metal fatigue when subjected to bending, compared to single strand conductors.
Innovation Solution
An electrical conductor design featuring an inner conductive element coated with a first polymer layer, drawn into block arc-shaped segments, and spaced around a central axis with a second polymer layer filling the gaps between segments to form a substantially annular cross-sectional area, reducing interstitial space and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-strand conductors are used, then metal fatigue resistance is improved, but conductor material per cross-sectional area is reduced
Solution Approach 1:
The conductor is divided into multiple individual strands that are twisted together to form a multi-strand configuration. This segmentation allows the conductor to resist metal fatigue while maintaining adequate conductive material cross-sectional area by optimizing the arrangement and density of the strands.
Solution Approach 2:
Multiple conductor strands are nested within each other in a concentric or twisted arrangement, with inner strands positioned within the structure formed by outer strands. This nesting maximizes the use of conductor material within the available cross-sectional area while maintaining the flexibility and fatigue resistance of multi-strand construction.
2Adaptability or versatility
If multi-strand conductors are used, then flexibility is improved, but interstitial space increases
Solution Approach 1:
The conductor strands are arranged in an asymmetric twisted or spiral pattern rather than a symmetric grid, which optimizes the distribution of interstitial space. This asymmetric arrangement maintains flexibility for bending and movement while minimizing the volume of non-conductive gaps between strands.
Solution Approach 2:
The conductor strands are formed with curved or helical geometries rather than straight rigid forms. This curvature allows the multi-strand conductor to flex and bend more easily while the rounded shapes of the strands help pack them more efficiently, reducing interstitial space compared to angular or flat strand configurations.
3Reliability
If multi-strand conductors are used, then resistance to bending fatigue is improved, but fluid flow between strands is enabled
Solution Approach 1:
The interstitial spaces between conductor strands, which could allow harmful fluid ingress, are intentionally filled with beneficial materials such as moisture-resistant compounds, lubricants, or protective coatings. This converts the potential harm of fluid flow into a benefit by using the same spaces to deliver protective substances that prevent corrosion and enhance flexibility.
Solution Approach 2:
The conductor strands or the material filling the interstitial spaces are designed with controlled porosity characteristics. This allows the structure to accommodate slight movements and bending while maintaining resistance to harmful fluid penetration, as the porous structure can absorb or repel fluids in a controlled manner rather than allowing unrestricted flow.
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 design increases the percentage of the cross-sectional area available for carrying current and reduces fluid flow and metal fatigue, improving the efficiency and durability of the electrical conductor.
Implementation Method 1
A first polymer layer can be disposed circumferentially about the inner electrically conductive element
Implementation Method 2
A second polymer layer can be disposed between the electrical conductor segments, wherein the second polymer and the electrical conductor segments together define a substantially annular cross-sectional area
Implementation Method 3
drawing an electrical conductor material into a plurality of electrically conductive segments each electrical conductor segment having a substantially block arc cross-sectional area, and annealing the electrically conductive segments
Data Source
AI summary
Electrical conductors and processes for making and using same. In some examples, the electrical conductors can include an inner electrically conductive element, which can define a central longitudinal axis. A first polymer layer can be disposed circumferentially about the inner electrically conductive element. A plurality of electrical conductor segments can be disposed about the first polymer layer and spaced around the central longitudinal axis. A second polymer layer can be disposed between the electrical conductor segments. The second polymer layer and the electrical conductor segments together can define a substantially annular cross-sectional area and an outer perimeter surface. An electrical insulator can be disposed about the outer perimeter surface defined by the second polymer layer and the electrical conductor segments.