Conductive Composite Structure With Insulated Connector Interface
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Solution Overview
Problem
The existing composite material structures with conductors embedded in conductive resins face issues with galvanic corrosion due to contact between dissimilar metals when exposed to liquids, particularly at the connecting portions where the conductor meets the conductive resin.
Innovation Solution
A composite material structure is developed with a conductive resin portion containing conductive fibers, a conductor embedded within, and an insulator formed from insulating material partially embedded in the resin to prevent contact between the conductor and the conductive resin, thereby avoiding galvanic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conductor is embedded in a conductive resin portion without additional insulation, then the electrical connection is simplified and device complexity is reduced, but galvanic corrosion occurs at the contact portion between the conductor and conductive resin when exposed to liquids
Solution Approach 1:
An insulator is introduced as an intermediary component between the conductor and the conductive resin portion. This insulator prevents direct contact between the conductor and conductive resin, eliminating the galvanic corrosion pathway while maintaining the embedded conductor structure for electrical connection purposes
2Reliability
If an insulator is added to prevent contact between the conductor and conductive resin, then galvanic corrosion is prevented and reliability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The insulator is merged with the conductor as a integrated component unit before embedding into the conductive resin. This combining of the insulator and conductor reduces the number of separate assembly steps and simplifies the overall manufacturing process while maintaining the protective insulation 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 prevents galvanic corrosion by isolating the conductor from the conductive resin with an insulator, ensuring reliable electrical connections while maintaining the structural integrity and preventing corrosion even when exposed to moisture.
Implementation Method 1
a contact state equivalent to the contact between dissimilar metals is produced at a portion such as a basal portion of the connecting portion where the conductor exposed as the connecting portion and the conductive resin portion contact with each other. When a liquid such as water gets onto that portion, this can possibly cause galvanic corrosion due to the contact between dissimilar metals.
Data Source
AI summary
A composite material structure that prevents occurrence of galvanic corrosion while exposing a part of a conductor embedded in a conductive resin portion as a connecting portion, is provided. The composite material structure includes a conductive resin portion formed of an electrically conductive reinforced resin in which conductive fibers are contained in a base material, a conductor formed of a conductive material and embedded in the conductive resin portion with a part of the conductor exposed as a connecting portion for electrical connection with another component, and an insulator that is formed of an insulating material and that is at least partially embedded in the conductive resin portion so as to be interposed between the conductive reinforced resin and the conductor so as to prevent the connecting portion of the conductor from contacting the conductive reinforced resin.