Battery Wire PVC Cover Suppresses Capillary Electrolyte Leakage
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Solution Overview
Problem
Existing battery routing electric wires face issues with electrolytic solution leakage leading to device breakage due to capillary phenomenon, and current countermeasures either limit terminal orientation or increase processing steps.
Innovation Solution
A battery routing electric wire with a single conductive wire conduction portion and a polyvinyl chloride cover portion, which suppresses capillary absorption of the electrolytic solution by changing it into water through chemical reaction, reducing the risk of liquid reaching connected devices without requiring specific terminal orientation or additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping surface side of terminals is oriented to face away from the battery or a water-absorbent polymer sheet is provided inside the electric wire, then device breakage due to electrolytic solution leakage is prevented, but terminal orientation is limited or processing steps increase
Solution Approach 1:
The harmful electrolytic solution is extracted from the system by using the polyvinyl chloride cover portion to chemically convert it into harmless water through reaction with KOH, eliminating the need for complex sealing structures or orientation constraints
Solution Approach 2:
The polyvinyl chloride cover portion acts as an intermediary substance that reacts with the electrolytic solution (KOH), converting it into water and thereby protecting the device without requiring direct physical barriers or orientation control
2Strength
If a twisted wire structure is used for the conduction portion, then flexibility and strength are improved, but capillary absorption of electrolytic solution increases
Solution Approach 1:
The potential harm of capillary absorption is converted into a benefit by using the single wire structure to minimize capillary effects, then utilizing the polyvinyl chloride cover's chemical reaction capability to actively neutralize any electrolytic solution that might come into contact with the wire
Solution Approach 2:
The wire structure parameter is changed from twisted to single wire, fundamentally altering the capillary characteristics and reducing electrolytic solution absorption while maintaining electrical conduction function
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 effectively reduces the risk of device breakage by limiting liquid travel to less than 200 mm, even after 72 hours of immersion, and further reduces this risk with a polymerization degree of polyvinyl chloride equal to or greater than 1000, thereby preventing an increase in processing steps and ensuring terminal orientation flexibility.
Implementation Method 1
since the cover portion is made of the polyvinyl chloride, the alkaline electrolytic solution is changed into water by a chemical reaction
Implementation Method 2
since the conduction portion is formed of the single wire, the electrolytic solution is difficultly to be sucked up due to the capillary phenomenon compared to a case of a twisted wire
Data Source
AI summary
A battery routing electric wire is routed between a battery having an alkaline electrolytic solution and a device. The battery routing electric wire includes: a conduction portion formed of a single wire; and a cover portion that covers the conduction portion and is made of polyvinyl chloride.