Electric Wire Terminal Resin Coating for Corrosion and Width
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric wires with terminals face challenges in balancing corrosion prevention and terminal width, as exposing distal end surfaces of side wall portions can compromise corrosion resistance while coating the outer side surfaces with resin increases terminal width.
Innovation Solution
An electric wire with a terminal design that includes a crimp terminal crimped to the core and cover wires, with a resin that integrally covers the core wire and crimp terminal, specifically covering the distal end surfaces of side wall portions while minimizing resin application on outer side surfaces to reduce terminal width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer side surfaces of the side wall portions are coated with resin, then corrosion prevention performance is improved, but terminal width is increased
Solution Approach 1:
The resin coating is applied selectively to only the distal end surfaces of the side wall portions, which are the areas most susceptible to corrosion, while deliberately excluding the outer side surfaces. This localized coating approach provides corrosion protection where it is most needed without increasing the overall terminal width, as the resin does not extend beyond the original boundaries of the side wall portions.
2Length of moving object
If the distal end surfaces of the side wall portions are exposed, then terminal width is reduced, but corrosion prevention performance is lowered
Solution Approach 1:
The invention applies resin coating locally to the distal end surfaces of the side wall portions, which are the cut surfaces most vulnerable to corrosion. By targeting only these specific areas for coating, the invention maintains the compact terminal width while providing corrosion protection precisely where the exposed surfaces create vulnerability.
3Reliability
If resin is applied to cover the connecting portion, then corrosion prevention is improved, but manufacturing complexity increases
Solution Approach 1:
The coating process is designed to apply resin only to specific distal end surfaces of the side wall portions rather than the entire connecting portion. This localized coating approach simplifies the manufacturing process by reducing the coating area, minimizing material usage, and enabling more efficient curing, while still achieving effective corrosion protection at the most vulnerable points.
Data Source
AI summary
An electric wire with a terminal includes: an electric wire having a core wire, and a cover; a crimp terminal having a core wire crimping portion which is crimped to the core wire, a cover crimping portion which is crimped to the cover, and a connecting portion which extends from the core crimping portion to the cover crimping portion; and a resin which integrally covers the core wire and the crimp terminal. The core wire has an intermediate portion which extends between the core crimping portion and the cover crimping portion. The connecting portion has a bottom wall portion and a pair of side wall portions which extend in a height direction of the crimp terminal from end portions of the bottom wall portion in a width direction.