Conductive Line Shield Structure Preventing Electrolytic Corrosion
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Solution Overview
Problem
The use of copper and aluminum foils in shielded electric wires for automobiles leads to electrolytic corrosion, increasing costs when attempting to prevent it with tin plating, as uniform coverage is difficult and costly.
Innovation Solution
A conductive line shield structure featuring a shielding member with an insulative base material and aluminum foil, where a plated layer on the aluminum foil contacts a copper conductive line, forming an enclosure type configuration that prevents electrolytic corrosion at a lower cost by ensuring even plating coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tin plating is applied to the drain wire to prevent electrolytic corrosion between copper and aluminum, then corrosion protection is improved, but manufacturing cost increases and plating uniformity becomes difficult to achieve
Solution Approach 1:
The patent introduces a plated layer on the aluminum foil side that serves as an intermediary barrier between copper and aluminum, preventing direct contact and electrolytic corrosion. This mediator approach allows corrosion protection without requiring expensive and difficult-to-apply plating on the drain wire itself
Solution Approach 2:
Instead of applying plating to the copper drain wire (traditional approach), the patent inverts the plating location to the aluminum foil side of the shielding member. This reversal makes the plating process easier and more uniform while achieving the same corrosion prevention function
2Ease of manufacture
If aluminum foil is used instead of copper foil for the shielding layer, then material cost is reduced, but electrolytic corrosion occurs when in contact with copper drain wire
Solution Approach 1:
The plated layer on the aluminum foil acts as an intermediary barrier that prevents direct electrochemical contact between copper and aluminum, eliminating electrolytic corrosion while maintaining the cost advantage of using aluminum foil instead of copper foil for the shielding layer
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
This solution effectively reduces costs by preventing electrolytic corrosion while maintaining a high shielding function, allowing for the use of aluminum foil at a lower cost and improving electrical insulation by collectively enclosing conductive lines.
Implementation Method 1
implementation of combination of the drain wire 3 made of the copper electric wire and the shield layer 4 made of the inexpensive aluminum foil as a simple inexpensive countermeasure has a problem of causing electrolytic corrosion by copper and aluminum
Data Source
AI summary
A conductive line shield structure includes a first conductive line, a second conductive line and a shielding member. The first conductive line includes a conductive part and an insulative part. At least a surface of the second conductive line is made of copper. The shielding member, is a sheet including an insulative base material and an aluminum foil, and is wrapped so as to enclose the first conductive line and the second conductive line therein. A plated layer is provided on a surface of the aluminum foil and is in contact with the second conductive line.