Sealed Conductor With Hexagonal Wire Arrangement
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Solution Overview
Problem
Conventional stranded conductors with lubricating fillers face issues of mechanical instability and shape changes under external forces, leading to unwanted electrical characteristics and coating challenges due to hexagonal cross-sections, and are costly to produce with multiple wire types and expensive filler materials.
Innovation Solution
A stranded conductor design using two types of wires with controlled deformation to maintain a circular cross-section, where smaller diameter wires are positioned at vertices to support larger wires, reducing interstitial spaces and requiring minimal sealing material, while ensuring dimensional stability and ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stranded conductors use lubricating fillers to seal gaps between wires, then moisture impermeability is improved, but mechanical stability deteriorates causing wire shifts and shape changes under external forces
Solution Approach 1:
The invention removes the lubricating filler material from the cable core, eliminating the source of mechanical instability while maintaining moisture protection through a different structural approach using compacted wire arrangements and alternative sealing methods that do not compromise wire stability
Solution Approach 2:
The invention changes the physical state and arrangement parameters of the wire core by compacting the stranding to reduce interstitial spaces to less than 15% of the cross-sectional area, and using wires with specific diameter ratios (0.7-0.9 times the outer layer wire diameter) to achieve both stability and sealing without lubricating fillers
2Shape
If conventional stranded conductors use multiple wire types with different diameters to achieve circular cross-section, then shape stability is improved, but device complexity increases
Solution Approach 1:
The invention applies local quality by using two distinct wire types with specific characteristics at different positions: larger diameter wires (D) for the outer layer providing structural stability, and smaller diameter wires (0.7-0.9D) for inner layers filling spaces and achieving compact circular geometry, with the arrangement optimized for dimensional stability
Solution Approach 2:
The invention creates a composite wire structure combining two types of conductive wires with different diameters in a specific geometric arrangement (hexagonal close-packing pattern), achieving both circular cross-section and mechanical stability while limiting complexity to only two wire types rather than multiple variations
3Productivity
If conventional stranded conductors use hexagonal wire arrangement to pack wires densely, then manufacturing efficiency is improved, but shape stability deteriorates resulting in non-circular cross-section
Solution Approach 1:
The invention introduces asymmetry in wire diameters within the hexagonal arrangement - using smaller diameter wires for inner layers and larger diameter wires for outer layers - which breaks the symmetry of conventional uniform hexagonal packing and enables both dense manufacturing and circular cross-section geometry
Data Source
Figure 1~2B
Figure 3~5
Figure 6~7
AI summary
The invention is directed to stranded conductor (2) comprising a specific number of a first type of wire (5) which, when looking at a cross-section of the stranded conductor, are arranged in a hexagonal pattern around a central wire (7) by at least two layers. The wires arranged at the vertices of the hexagonal pattern are of a second type of wire (6) having in principle a smaller diameter than the first type of wires (5). The interstitial spaces (10) between the first and the second wires are filled by a sealing agent (3).