Terminal-Equipped Wire Resin Sealing for Charging Inlet Moisture Blocking
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Solution Overview
Problem
Terminal-equipped wires for charging inlets face challenges with water stopping performance due to increased current flow, which leads to higher temperatures and reduced effectiveness of existing water stop portions, especially when dealing with large-diameter wires.
Innovation Solution
A terminal-equipped wire design featuring a molded resin portion with a primer layer, using olefin-based resins like polyethylene or polypropylene for the insulation coating and polyurethane or polypropylene for the primer, enhances water stopping performance by improving bonding and withstanding increased inner pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the wire diameter is increased to handle larger current, then the current carrying capacity is improved, but the bonding between water stop portion and wire becomes difficult without gaps
Solution Approach 1:
The water stop portion is divided into multiple sections: a molded resin portion that directly contacts the insulation coating, and a separate adhesive layer that bonds the terminal to the molded resin portion. This segmentation allows each part to optimize its function - the molded resin provides structural integrity for large diameter wires, while the adhesive ensures complete bonding coverage.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the terminal and the molded resin portion. This adhesive layer fills gaps and ensures complete bonding coverage, solving the bonding difficulty caused by increased wire diameter while maintaining electrical insulation and environmental protection.
2Power
If the current flow is increased, then the power transmission capability is improved, but the temperature increases and reduces water stopping performance
Solution Approach 1:
The water stop portion uses a composite structure combining molded resin and adhesive materials with complementary properties. The molded resin provides thermal stability and structural support, while the adhesive maintains bonding integrity at elevated temperatures. This composite approach ensures water stopping performance is maintained even when temperature increases due to high current flow.
3Strength
If a primer layer is added between the molded resin portion and terminal, then the bonding performance is improved, but the device complexity increases
Solution Approach 1:
The primer layer modifies the surface properties of either the terminal or molded resin portion to enhance adhesion. By changing the surface parameters (roughness, chemical composition, or energy), the bonding strength is significantly improved without requiring complex structural modifications. The primer layer is applied as a thin coating that does not substantially increase overall device complexity.
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 effectively suppresses moisture intrusion and maintains high water stopping performance over a long period, even under severe environmental conditions, as demonstrated by maintaining pressure integrity in tests at elevated temperatures and humidity.
Implementation Method 1
a primer layer provided between an inner peripheral surface of the molded resin portion and an outer peripheral surface of the terminal
Implementation Method 2
The water stop portion suppresses the corrosion of the conductor and the terminal due to the adhesion of moisture to the connection point of the conductor and the terminal
Implementation Method 3
a wire including a conductor and an insulation coating, the insulation coating having an olefin-based resin as a main component
Data Source
AI summary
A terminal-equipped wire for charging inlet is provided with a wire including a conductor and an insulation coating, and a terminal to be connected to the conductor exposed from an end part of the wire. The insulation coating has an olefin-based resin as a main component. The terminal-equipped wire is further provided with a molded resin portion for covering a region from a connection point of the conductor and the terminal to the insulation coating, and a primer layer provided between an inner peripheral surface of the molded resin portion and an outer peripheral surface of the terminal. The inner peripheral surface of the molded resin portion and an outer peripheral surface of the insulation coating are directly in contact.