Sealed Electric Terminal Assembly with Thiol Coating
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Solution Overview
Problem
Galvanic corrosion occurs at the interface between aluminum and copper-based metal components in electrical connections, particularly at cable terminals, due to moisture exposure, which compromises the integrity of the connection.
Innovation Solution
A conductive cable terminal assembly with a coating composition derived from a free radical polymerization reaction, comprising an oligomer with active unsaturated bonds, a monomer with unsaturated bonds, and a compound with multiple thiol groups, applied over the interface to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a crimp interface connection of aluminum cable core to copper terminal is used, then weight and cost savings are achieved, but galvanic corrosion occurs at the metal interface due to moisture exposure
Solution Approach 1:
The patent applies a multi-component coating system comprising a primer layer and a topcoat layer as an intermediary barrier between the aluminum cable core and copper terminal. The primer layer adheres to the metal substrate and provides corrosion inhibition, while the topcoat layer provides additional environmental protection. This intermediary coating system prevents direct contact between dissimilar metals and moisture/electrolytes, eliminating galvanic corrosion while maintaining the aluminum-copper connection configuration.
Solution Approach 2:
The patent employs a composite coating structure consisting of multiple layers with different functional properties. The primer layer contains corrosion inhibitors and adhesion promoters specifically formulated for metal substrates, while the topcoat layer provides enhanced environmental resistance. This composite material approach combines the benefits of different materials to simultaneously achieve adhesion, corrosion protection, and environmental sealing at the aluminum-copper interface.
2Object-affected harmful factors
If conventional sealing materials are applied over the metal interface, then moisture protection is improved, but complete sealing is difficult to achieve and galvanic corrosion persists
Solution Approach 1:
The patent applies different coating formulations to different locations and surfaces within the connection assembly. The primer layer is specifically designed with adhesion promoters and corrosion inhibitors for direct application on metal surfaces (cable core and terminal), while the topcoat layer is formulated for enhanced environmental resistance. This localized quality approach ensures that each layer performs its specific function optimally, creating a comprehensive protection system that completely seals the interface against moisture and prevents galvanic corrosion.
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 coating composition effectively seals the interface, preventing moisture ingress and reducing galvanic corrosion, thereby enhancing the durability and reliability of the electrical connection.
Implementation Method 1
a coating is disposed over the conductive connection interface that is the product of a free radical polymerization reaction of a coating composition applied over the conductive connection interface
Data Source
AI summary
A wire terminal assembly is disclosed in which a conductive terminal is connected to a conductive cable core along a conductive connection interface. A coating is disposed over the conductive connection interface that is the product of a free radical polymerization reaction of a coating composition applied over the conductive connection interface, the coating composition including: (1) an oligomer comprising at least two active unsaturated bonds, (2) a monomer comprising an unsaturated bond, and (3) a compound comprising a plurality of thiol groups.