Terminal-Equipped Coated Wire Crosslink Density
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Solution Overview
Problem
The existing wire harnesses with aluminum conductors and copper terminal fittings face corrosion issues due to contact between dissimilar metals, and conventional anticorrosive agents deteriorate when exposed to oil, leading to inadequate anti-corrosion performance.
Innovation Solution
A terminal-equipped coated wire with a cured product of curable resin as the anticorrosive agent, having a crosslink density between 0.6×10−5 to 4×10−4 mol/cm3, is used to seal the contact portion between the aluminum conductor and the tin-plated copper terminal fitting, ensuring effective oil resistance and preventing peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional anticorrosive agent (silicon resin or acrylic resin) is used to seal the exposed conductor portion, then corrosion at the electrical connection portion is prevented, but the adhesiveness between the anticorrosive agent and the conductor or terminal deteriorates when oil adheres to the sealed portion
Solution Approach 1:
The patent applies parameter changes by controlling the crosslink density of the cured resin within a specific range (0.6×10^-5 to 4×10^-4 mol/cm³). This parameter optimization ensures the anticorrosive agent maintains sufficient adhesiveness to metal surfaces while achieving adequate oil resistance, resolving the contradiction between initial corrosion protection and long-term stability under oil exposure.
Solution Approach 2:
The patent uses composite materials by combining the cured resin (anticorrosive agent) with specific metal surfaces (conductor and terminal fitting). The composite structure of the resin-metal interface, when properly formulated with appropriate crosslink density, maintains strong adhesion even in the presence of oil, preventing both corrosion and delamination.
2Object-affected harmful factors
If the crosslink density of the cured product is increased to improve oil resistance, then oil penetration is prevented, but cracking occurs in the film of the anticorrosive agent
Solution Approach 1:
The patent applies parameter changes by defining an optimal range for crosslink density (0.6×10^-5 to 4×10^-4 mol/cm³). Within this range, the cured product achieves sufficient oil resistance while maintaining film flexibility and preventing cracking. The lower bound ensures adequate adhesion, while the upper bound prevents excessive brittleness.
3Stability of the object's composition
If the crosslink density of the cured product is decreased to prevent cracking, then film flexibility is maintained, but oil penetration increases and peeling occurs
Solution Approach 1:
The patent applies parameter changes by establishing the minimum crosslink density threshold (0.6×10^-5 mol/cm³) required to achieve adequate oil resistance. Below this threshold, the resin network is too loose to effectively prevent oil penetration and adhesion failure occurs. The specified range ensures both flexibility and oil resistance.
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 solution provides a wire harness with enhanced anti-corrosion performance by maintaining adhesiveness and preventing oil penetration, thus preventing corrosion and cracking, even in in-vehicle environments exposed to oil.
Implementation Method 1
the anticorrosive agent is composed of a cured product of a curable resin, the cured product having a crosslink density within a range of 0.6×10−5 to 4×10−4 (mol/cm3)
Data Source
AI summary
A terminal-equipped coated wire having an exposed conductor portion at an end portion of a coated wire in which a conductor is coated with a coating material, a terminal fitting—connected to the conductor at the exposed conductor portion, and an anticorrosive agent with which a contact portion between the conductor and the terminal fitting is sealed, wherein an anticorrosive agent which is composed of a cured product of a curable resin and in which the cured product has a crosslink density within a range of 0.6×10−5 to 4×10−4 (mol/cm3) is used as the anticorrosive agent.