Twisted Wire Conductor with Recessed Surface for Lightweight Flying Objects
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Solution Overview
Problem
Existing small-diameter electric wires with a conductor total cross-sectional area of 2 mm^2 or less face challenges in achieving high reliability and light weight, particularly in applications like flying objects where weight increases dramatically affect energy consumption and safety.
Innovation Solution
A twisted wire conductor with a total cross-sectional area of 2 mm^2 or less, combined with a covering member made from a resin material with a flexural modulus of 0.6 GPa or more, featuring recesses on its outer surface with a depth of 5% or less of its maximum diameter, and a compression ratio of 90% or more, to enhance mechanical strength and reduce springback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the conductor total cross-sectional area is reduced to achieve light weight, then weight decreases and energy consumption reduces, but reliability deteriorates due to insufficient mechanical strength and increased susceptibility to damage
Solution Approach 1:
The patent employs composite material structures including the resin covering member combined with the twisted wire conductor, creating a composite cable harness that achieves both light weight and high reliability. The resin material provides protective functions while the twisted conductor maintains electrical performance, together forming a reliable yet lightweight assembly suitable for flying objects
Solution Approach 2:
The patent introduces recesses at specific locations on the outer peripheral surface of the twisted wire conductor, creating local structural variations that enhance adhesion between the conductor and covering member. These localized recesses improve mechanical strength and reliability at critical points without increasing the overall weight of the conductor
2Reliability
If the adhesive force between insulator layer and conductor is increased to prevent disconnection, then reliability improves, but weight increases due to additional material requirements
Solution Approach 1:
The recesses are strategically positioned at locations where strand conductor boundaries exist on the outer peripheral surface of the twisted wire conductor. This localized approach concentrates adhesion enhancement at critical interfaces without requiring additional adhesive materials throughout the entire conductor surface, thereby improving reliability while minimizing weight increase
Solution Approach 2:
The recesses are pre-formed on the conductor surface before the resin covering member is applied. This preliminary structural preparation ensures optimal adhesion between the conductor and covering member without requiring additional weighting or complex bonding processes, achieving strong integration while maintaining light weight
3Reliability
If the flexural modulus of the covering member is increased to maintain shape stability, then reliability improves, but weight increases due to thicker or denser material requirements
Solution Approach 1:
The patent specifies that the resin covering member has a flexural modulus of 0.6 GPa or more, optimizing the mechanical properties of the covering material to provide sufficient shape stability and protection. By carefully selecting and controlling the flexural modulus parameter within this range, the patent achieves reliable shape maintenance while avoiding excessive material thickness or density that would increase weight
Data Source
AI summary
There is provided an electric wire having a conductor total cross-sectional area of 2 mm2 or less and high reliability. The electric wire includes: a twisted wire conductor (2) including a plurality of strand conductors (21 to 27) twisted together with each other and having a total cross-sectional area of the plurality of strand conductors of 2 mm2 or less; and a covering member (3) made from a resin material having a flexural modulus of 0.6 GPa or more and covering the twisted wire conductor so that an inner wall thereof is in contact with an outer peripheral surface of the twisted wire conductor, wherein the twisted wire conductor (2) has, on an outer peripheral surface thereof, recesses having a maximum depth of 5% or less of a maximum diameter of the twisted wire conductor in a cross section perpendicular to a length direction of the twisted wire conductor and containing boundaries of the plurality of strand conductors.