Aluminum Wire Terminal Coating for Corrosion Resistance
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Solution Overview
Problem
Terminal-attached electric wires with aluminum alloy conductors and copper or copper alloy terminal members face corrosion issues due to cell formation, which is not effectively addressed by conventional insulating methods, leading to increased weight and manufacturing complexity.
Innovation Solution
A terminal-attached electric wire with a conductor made of aluminum or aluminum alloy and a terminal member made of copper or copper alloy, featuring a coating layer of electrically conductive material with an oxide film thicker than 20 nm, which suppresses corrosion by reducing oxygen reduction current and eliminating the need for additional insulating members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating members are used to cover the conductor to suppress corrosion, then corrosion resistance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the insulating member from the structure by applying a coating layer directly to the terminal member surface. The coating layer with oxide film provides corrosion protection without requiring separate insulating components, thus simplifying the overall structure while maintaining corrosion resistance.
Solution Approach 2:
The patent uses a composite structure consisting of the terminal member with a coating layer and oxide film formation. This composite material approach creates a protective surface structure that provides corrosion resistance through the oxide film while eliminating the need for additional insulating members.
2Reliability
If insulating members are added to prevent corrosion, then corrosion resistance is improved, but productivity decreases due to additional assembly steps
Solution Approach 1:
The patent merges the corrosion protection function directly into the terminal member by forming a coating layer and oxide film on its surface. This integration eliminates the need for separate insulating members and their assembly steps, thereby improving manufacturing efficiency while maintaining corrosion resistance.
Solution Approach 2:
The coating layer and oxide film are formed on the terminal member surface in advance during manufacturing. This preliminary protection structure is built-in before assembly, eliminating subsequent steps of adding and securing insulating members, thus improving productivity.
3Weight of moving object
If aluminum alloy conductors are used to reduce weight, then weight is reduced, but corrosion resistance deteriorates due to cell formation with copper terminal members
Solution Approach 1:
The coating layer and oxide film serve as an intermediary between the aluminum alloy conductor and copper terminal member. This intermediate protective layer prevents direct contact between dissimilar metals, eliminating galvanic cell formation and corrosion while allowing the lightweight aluminum conductor to be used.
4Reliability
If coating layer with oxide film is formed on terminal member, then corrosion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent controls the oxide film thickness within a specific range (50-500 nm) to achieve optimal protection. By specifying parameter ranges for coating thickness and oxide film formation, the patent balances corrosion resistance with manufacturing feasibility, avoiding overly complex processes while ensuring adequate protection.
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 solution enhances corrosion resistance, productivity, and reduces weight by eliminating the need for insulating members, while maintaining electrical conductivity, even in non-waterproof environments.
Implementation Method 1
an oxide film of the electrically conductive material formed in a surface of the coating layer
Implementation Method 2
the electrically conductive material being a metal or an alloy which forms an oxide film having a thickness of more than or equal to 20 nm in a surface thereof when 50 g/L of salt water at 35° C. is sprayed for 96 hours
Data Source
AI summary
Provided is a terminal-attached electric wire including: an electric wire having a conductor made of aluminum or an aluminum alloy whose outer circumference is covered with an insulating layer; and a terminal member made of copper or a copper alloy and attached to a conductor-exposed portion exposed from the insulating layer at an end portion of the electric wire. The terminal member includes a coating layer made of an electrically conductive material and formed at a terminal-exposed portion except for a place of contact with the conductor in a surface of the terminal member, and an oxide film of the electrically conductive material formed in a surface of the coating layer. The electrically conductive material is a metal or an alloy which forms an oxide film having a thickness of more than or equal to 20 nm in a surface thereof.