Terminal Block Bus Bar Sealing with Partial Tin Plating
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Solution Overview
Problem
Conventional terminal blocks with rubber-based adhesives for sealing face challenges in maintaining sealing properties when exposed to high temperatures due to deterioration and softening, exacerbated by metal ions from the bus bar, leading to potential liquid intrusion.
Innovation Solution
A terminal block design featuring a bus bar with a Cu or Cu alloy base material and a partial Sn-based plated layer, where the base material is exposed at the sealing region, preventing surface contact between the rubber-based adhesive and Sn-based plated layer, thus reducing reaction and deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber-based adhesive is used as a sealing portion to fill the gap between the resin portion and bus bar, then sealing properties are improved, but the adhesive deteriorates and softens when exposed to high temperatures for long periods
Solution Approach 1:
The patent introduces a plated layer (such as Sn, Ni, or Zn) on the bus bar surface as an intermediary barrier between the rubber-based adhesive and the copper base material. This plated layer prevents direct contact and chemical reactions between the adhesive and copper ions, thereby suppressing adhesive deterioration and maintaining sealing properties in high-temperature environments.
Solution Approach 2:
The patent changes the surface composition parameter of the bus bar by applying a plated layer with specific material properties (Sn, Ni, Zn, or their alloys). This parameter change modifies the chemical interaction characteristics at the adhesive-bus bar interface, reducing catalytic effects and preventing harmful reactions that would otherwise accelerate adhesive degradation at high temperatures.
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 configuration effectively suppresses the deterioration of the rubber-based adhesive sealing portion, maintaining sealing properties even in heated environments and preventing liquid intrusion.
Implementation Method 1
a sealing portion filling a gap between the embedded portion and the resin portion
Implementation Method 2
the sealing portion made of a rubber-based adhesive and the Sn-based plated layer are not in surface contact with each other, and the likelihood that the rubber-based adhesive will react with metal ions and generate sulfide, oxide, chloride, or the like is low
Data Source
AI summary
A terminal block in which outflow of a sealing portion made of a rubber-based adhesive can be suppressed even when exposed to a heated environment, and the sealing properties can be maintained. The terminal block includes a housing having a resin portion, a bus bar, and the sealing portion. The bus bar integrally includes an embedded portion embedded in the resin portion, and a connecting portion projecting outward from the resin portion. The sealing portion fills a gap between the embedded portion and the resin portion. The sealing portion is made of a rubber-based adhesive. The bus bar includes a base material made of Cu or a Cu alloy, and an Sn-based plated layer made of Sn or an Sn alloy and partially covering a surface of the base material. The base material is exposed at a sealing region in contact with the sealing portion.