Copper Alloy Metallic Connecting Lines for High-Sulfur Oil Corrosion
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Solution Overview
Problem
Motor vehicle control units with conventional copper alloys fail due to corrosion when exposed to high-sulfur oils, leading to connection failures and short circuits in high-performance transmission systems.
Innovation Solution
Employing copper alloys with zinc content greater than 10% for metallic connecting lines, which enhances corrosion resistance in sulfur-rich environments, using materials like nickel silver or brass for connecting lines and encapsulating them within a double-walled plastic housing with a special liquid seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional copper alloys with low alloy content (less than 10-12%) are used for metallic connecting lines, then electrical conductivity is high and cost is low, but corrosion resistance in high-sulfur oil environments is poor
Solution Approach 1:
The patent changes the chemical composition parameters of the copper alloy by increasing the alloy content to more than 10-12%, specifically incorporating elements like zinc, aluminum, nickel, or tin. This parameter change transforms the material properties to achieve both high electrical conductivity and enhanced corrosion resistance in sulfur-containing lubricants.
Solution Approach 2:
The patent uses composite copper alloys combining copper with multiple alloying elements (zinc, aluminum, nickel, tin) in specific proportions. This composite material approach creates a synergistic effect where the alloying elements provide corrosion resistance while copper maintains electrical conductivity, solving the contradiction between conductivity and corrosion resistance.
2Reliability
If copper alloys with alloy content greater than 10% are used, then corrosion resistance improves, but material cost increases
Solution Approach 1:
The patent optimizes the alloy composition parameters by setting the alloy content threshold at more than 10-12%, which is the minimum level needed to achieve adequate corrosion resistance. This parameter optimization balances performance requirements with cost considerations, avoiding excessive alloying that would unnecessarily increase material costs.
Solution Approach 2:
The patent applies different alloy compositions to different connecting line applications based on their specific corrosion exposure levels. Connecting lines in high-sulfur environments receive the enhanced alloy formulation, while less critical applications may use standard compositions, optimizing cost-effectiveness across the entire system.
3Strength
If sulfur content in lubricant is increased to improve lubrication performance, then lubricating properties improve, but corrosion potential for copper materials increases
Solution Approach 1:
The patent converts the harmful effect of sulfur in lubricants into a beneficial outcome by developing copper alloys that are specifically resistant to sulfur corrosion. The alloying elements (particularly zinc and aluminum) form protective layers that prevent sulfur from attacking the copper, allowing the use of high-sulfur lubricants for improved lubrication without suffering corrosion damage.
Solution Approach 2:
The patent changes the chemical composition parameters of the connecting line material to create a material that is chemically compatible with high-sulfur lubricants. By adjusting the alloy content and specific element proportions, the material properties are optimized to resist corrosion while allowing the lubricant to maintain its high sulfur content for superior lubrication performance.
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
Prevents corrosion and ensures reliable operation of control units in environments with high-sulfur oils, maintaining electrical integrity and preventing failures such as weld dissolution and short circuits.
Implementation Method 1
A line made of a copper alloy with an alloy content of zinc greater than 10% is used as the metallic connecting line, which prevents sulfur corrosion on the metallic connecting line
Implementation Method 2
When sealing the passage of the metallic connecting lines in the housing, these are primarily injected in plastic or encapsulated with plastic
Data Source
AI summary
The invention relates to the use of a metallic connection line in a local control device in a motor vehicle structure, said local control device comprising at least one electronic control unit in a housing, and said metallic connection line electrically connecting the control unit in the housing to electrical components outside of said housing . The housing is arranged to be surrounded by oils that have sulphur contents of greater than approximately 1200 ppm, and copper alloys with an alloy content of greater than 10% are used for the metallic connection line, thus avoiding sulphur corrosion to said metallic connection line.