UV-Curable Anti-Corrosive Coating for Wire Terminal Joints
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Solution Overview
Problem
Corrosion occurs at the joint between coated wires with aluminum conductors and copper or copper alloy terminals due to peeling of anti-corrosive materials, creating pathways for water penetration and degradation of anti-corrosive effects.
Innovation Solution
An anti-corrosive material comprising an ultraviolet curable resin with a combination of photopolymerizable (meth)acrylate monomers and oligomers, including monofunctional, bifunctional, trifunctional, and polyfunctional compounds, and an anti-rust agent, is applied to the joint, providing a protective film that prevents peeling and ensures long-term corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anti-corrosive material is applied to protect the joint between aluminum conductor and copper terminal, then corrosion resistance is improved, but the material peels off over time creating pathways for water penetration
Solution Approach 1:
The patent uses a composite anti-corrosive material consisting of a thermoplastic polyamide resin base material combined with specific additives including silane coupling agents and adhesion promoters. This composite structure provides both initial corrosion protection and long-term bonding stability, preventing the peeling issue while maintaining reliability.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the anti-corrosive material by controlling moisture absorbing rate (1.0% or less), tensile shear strength (6 N/mm² or greater), and elongation rate (100% or greater). These parameter optimizations ensure the material maintains its protective function over time without peeling.
2Ease of manufacture
If thermoplastic polyamide resin is used as anti-corrosive material, then ease of manufacture is improved, but moisture absorption causes peeling and degradation of anti-corrosive effect
Solution Approach 1:
The patent enhances specific local properties of the thermoplastic polyamide resin by incorporating silane coupling agents and adhesion promoters at controlled concentrations. This creates localized regions with improved moisture resistance and bonding strength while maintaining the overall ease of manufacture and application of the thermoplastic material.
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 anti-corrosive material effectively prevents peeling and corrosion at the joint, maintaining anti-corrosive performance over time while allowing for instant curing and compatibility with existing connector housings.
Implementation Method 1
an ultraviolet curable resin including, as a main component, a polymerizable compound including at least one of a photopolymerizable (meth)acrylate monomer or a photopolymerizable (meth)acrylate oligomer
Data Source
AI summary
An anti-corrosive material includes an ultraviolet curable resin including, as a main component, a polymerizable compound including at least one of a photopolymerizable (meth)acrylate monomer or a photopolymerizable (meth)acrylate oligomer, and an anti-rust agent. The polymerizable compound includes a combination of a monofunctional (meth)acrylate monomer and a bifunctional (meth)acrylate monomer, or a combination of at least one of a monofunctional (meth)acrylate monomer or a bifunctional (meth)acrylate monomer and at least one of a trifunctional (meth)acrylate monomer or a polyfunctional (meth)acrylate monomer having four or more functional groups. The anti-corrosive material has a viscosity of 18,900 mPa·s or less.