Aluminum Wire Terminal Electrostatic Sealing Corrosion
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Solution Overview
Problem
Existing wire harnesses with aluminum wires face issues with electrolytic corrosion due to moisture ingress at the connection points with copper terminals, leading to insufficient sealing and anticorrosion properties, particularly when using conventional dispensing methods for sealing materials.
Innovation Solution
A terminal with a wire that employs an electrostatic attraction method to apply an ultraviolet curable resin as a sealing material around the wire-terminal connection portion, ensuring comprehensive coverage and curing with UV light to form a robust anticorrosion and waterproofing layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dispensing methods are used to apply sealing material, then the application process is simple, but the sealing material does not remain in place and comprehensive coverage is not achieved
Solution Approach 1:
The patent replaces the conventional mechanical dispensing system with an electrostatic application system. The sealing material is applied using electrostatic attraction between oppositely charged electrodes, enabling precise control of material placement and ensuring comprehensive coverage of the wire-terminal connection portion without the material running or pooling.
Solution Approach 2:
The patent changes the physical parameters of the sealing material by controlling its electrical charge state. By adjusting the voltage applied to the electrodes and the electrical properties of the sealing material, the system achieves optimal coverage and retention of the material in the target area.
2Reliability
If the compression ratio is increased to decrease contact resistance, then contact resistance decreases, but moisture can enter the crimp portion and cause electrolytic corrosion
Solution Approach 1:
The patent applies preliminary protective action by forming an anticorrosion portion before moisture can cause damage. The sealing material is applied in advance to cover the crimp portion and prevent moisture ingress, while the high compression ratio simultaneously achieves low contact resistance. This preliminary protection prevents the harmful electrolytic corrosion process from initiating.
Solution Approach 2:
The patent uses a composite structure combining the conductive terminal metal fitting with a protective sealing material. The terminal metal fitting provides electrical conductivity and mechanical connection, while the sealing material provides moisture barrier protection, creating a composite system that achieves both low contact resistance and corrosion resistance.
3Weight of moving object
If aluminum wire is used instead of copper wire, then vehicle weight is reduced and material recycling is easier, but oxide film thickness increases and contact resistance increases
Solution Approach 1:
The patent applies preliminary action by strongly caulking the aluminum conductor using conductor caulking pieces before final assembly. This preliminary caulking process destructs the oxide films on the aluminum wire surface, exposing fresh conductive metal and reducing contact resistance. This preparatory step enables aluminum wire to achieve comparable electrical performance to copper wire.
Solution Approach 2:
The patent changes the physical state of the aluminum conductor surface through mechanical caulking. The caulking process transforms the oxidized surface into a fresh, low-resistance contact surface, effectively changing the electrical properties of the connection interface to match or exceed copper wire performance.
4Reliability
If the conductor is strongly caulked to destroy oxide films, then contact resistance decreases, but the exposed conductor portion attracts moisture that reaches the crimp portion
Solution Approach 1:
The patent applies local quality by providing differentiated treatment to different portions of the wire-terminal assembly. The conductor caulking pieces provide strong local compression at the contact interface to reduce resistance, while the sealing material provides localized protection at the crimp portion to prevent moisture ingress. Each area receives the specific treatment it needs.
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 electrostatic attraction ensures the sealing material remains in place, providing a high sealing property and preventing moisture ingress, thus effectively preventing electrolytic corrosion and enhancing the anticorrosion and waterproofing of the terminal connections.
Implementation Method 1
a voltage is applied between the terminal metal fitting and a metal nozzle, and an electrified sealing material is supplied from the metal nozzle to the wire-terminal connection portion in a state of being attracted
Implementation Method 2
ensuring comprehensive coverage and curing with UV light to form a robust anticorrosion and waterproofing layer
Data Source
AI summary
A terminal with a wire having a high sealing property, a manufacturing method thereof, and a wire harness are provided. The terminal with the wire includes an aluminum wire and a crimp terminal. A resin covering member is removed from the aluminum wire to form a conductor exposed portion (a wire forming process). The crimp terminal is connected to the conductor exposed portion to form a wire-terminal connection portion (a wire-terminal connection process). Then, an anticorrosion portion is formed such that a voltage is applied between the crimp terminal and a metal nozzle and an electrified anticorrosion material is supplied from the metal nozzle to the wire-terminal connection portion in a state of being attracted (an anticorrosion material supply process). Further, the anticorrosion portion is formed by irradiating the anticorrosion material with an ultraviolet ray to be UV-cured (an anticorrosion material curing process).