Connector Lead Wire Corrosion Prevention via Electrolyte Space
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Solution Overview
Problem
Capacitor electrolytic solutions can leak and adhere to lead wires in connectors, causing corrosion due to the deterioration of rubber plugs used for sealing.
Innovation Solution
A connector design with a housing and spacer configuration that creates a space around the lead wire to prevent electrolytic solution from adhering, featuring a lead wire insertion hole with a larger inner diameter and a guide to ensure proper connection without contact, allowing the solution to discharge externally and preventing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber plug is used to seal the capacitor, then the electrolytic solution is contained, but the rubber plug deteriorates and allows leakage
Solution Approach 1:
The harmful element (rubber plug) is removed from the sealing system. Instead of relying on the rubber plug to contain the electrolytic solution, the design allows the solution to leak out through a controlled path (lead wire insertion hole) into a designated space, eliminating the need for a deteriorating sealing component.
Solution Approach 2:
The potential harm of electrolytic solution leakage is converted into a beneficial design feature. By providing a controlled leakage path and designated collection space, the design ensures that even if leakage occurs, it does not damage the lead wire or affect connector reliability. The leakage is redirected away from harmful areas.
2Device complexity
If the lead wire is directly connected to the terminal fitting, then the connection is simple, but the electrolytic solution adheres to the lead wire and causes corrosion
Solution Approach 1:
An intermediary space is introduced between the capacitor body and the lead wire connection point. This space, formed by the housing structure and lead wire insertion hole, acts as a buffer zone that intercepts the electrolytic solution before it can reach the lead wire, preventing corrosion while maintaining connection simplicity.
3Ease of manufacture
If the inner diameter of the lead wire insertion hole is larger than the outer diameter of the lead wire, then the lead wire can be easily inserted, but the electrolytic solution can adhere to the lead wire
Solution Approach 1:
The problem is solved by transitioning from a one-dimensional fit (hole diameter vs. wire diameter) to a three-dimensional solution. The housing structure creates a volumetric space around the lead wire base, providing multiple pathways for the electrolytic solution to disperse and preventing it from concentrating on the lead wire surface, thus maintaining both ease of insertion and corrosion resistance.
Data Source
AI summary
A connector (C) with a capacitor (20) has terminal fittings (10) held in a housing (30) and lead wires (22) of the capacitor (20) are connected. Spaces (S2) are formed around the bases of the lead wires (22) projecting from a main body (21) of the capacitor (20). An electrolytic solution might leak out from the capacitor (20). However, the electrolytic solution spreads away from the lead wires (22) into the spaces (S2) formed around the bases of the lead wires (22). Thus, the electrolytic solution will not adhere to and stay on the lead wires (22).