Small-Diameter Insulated Wire High Bending Resistance
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Solution Overview
Problem
Existing small-diameter insulated wires lack sufficient bending resistance, necessitating an increase in wire diameter to enhance this property.
Innovation Solution
A small-diameter insulated wire configuration featuring a copper alloy conductor with a breaking strength of 815 MPa or more, covered by a cross-linked fluororesin insulating layer with a breaking strength of 36.5 MPa or more and a thickness of 0.1 mm to 0.2 mm, achieving a conductor pullout force of 9 N/30 mm or less, which improves bending resistance while maintaining a small diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the diameter of the wire is increased to improve bending resistance, then bending resistance is improved, but the diameter becomes larger
Solution Approach 1:
The patent applies parameter changes by specifying precise ranges for conductor material composition (copper content 80-99 mass%, tin content 0.1-5 mass%), conductor breaking strength (≥815 MPa), insulating layer thickness (0.05-0.2 mm), and insulating layer breaking strength (≥36.5 MPa). These controlled parameter variations enable achieving high bending resistance while maintaining small wire diameter
Solution Approach 2:
The patent uses composite materials by combining copper alloy conductor with specific insulating layer materials (fluororesin, polyolefin, or cross-linked resin). The copper alloy itself is a composite of copper with tin or other elements, creating a material system that achieves both small diameter and high bending resistance through synergistic material properties
Data Source
AI summary
A small-diameter insulated wire has a small diameter and high bending resistance. In a small-diameter insulated wire having a conductor and an insulating layer covering the conductor, a cross-sectional area of the conductor is 0.08 mm2 or more and 0.4 mm2 or less, the conductor is a copper alloy having a breaking strength of 815 MPa or more, a breaking strength of the insulating layer is 36.5 MPa or more, a thickness of the insulating layer is 0.1 mm or more and 0.2 mm or less, and a conductor pullout force for drawing the conductor from the small-diameter insulated wire is 9 N/30 mm or less.