UV-Curable Anti-Corrosive Sealing for Compact Wire Terminals
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Solution Overview
Problem
Existing anti-corrosive materials for joints between aluminum coated wires and copper or copper alloy terminals require a thick coating to prevent corrosion, leading to increased dimensions that can prevent the material from being inserted into standard connector housings, necessitating a redesign of the housing.
Innovation Solution
An ultraviolet curable resin with a specific composition, including a combination of monofunctional, bifunctional, trifunctional, and polyfunctional (meth)acrylate monomers and oligomers, is used to form a sealing member that covers the joint, providing anti-corrosive protection while maintaining a low viscosity to prevent excessive thickness and allowing insertion into standard connector housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick anti-corrosive material coating is applied to cover the joint between metal terminal and wire, then corrosion prevention performance is improved, but the outer dimension of the joint increases excessively
Solution Approach 1:
The patent changes the physical and chemical parameters of the anti-corrosive material by using UV curable resin with specific viscosity control (18,900 mPa·s or less) and controlled thickness (0.5 mm or less), while maintaining adequate coverage (1.0 mm or more from joint surface). This allows sufficient corrosion protection with minimal dimension increase.
Solution Approach 2:
The patent uses a composite material system consisting of UV curable resin containing specific photopolymerizable (meth)acrylate monomers and oligomers, combined with metal terminal and wire. This composite structure achieves both corrosion resistance and dimensional control through the specific material properties of the resin composition.
2Reliability
If the outer dimension of the joint is increased to ensure adequate anti-corrosive material thickness, then corrosion prevention is improved, but the ability to insert into existing connector housing is lost
Solution Approach 1:
The patent controls the thickness parameter of the anti-corrosive material to be 0.5 mm or less, which is achieved through viscosity control (18,900 mPa·s or less) and controlled application. This parameter control ensures the joint with coating can be inserted into existing connector housing cavities without redesign.
Solution Approach 2:
The patent applies anti-corrosive material to specific critical areas of the joint rather than uniformly thick coating everywhere. The material is applied to ensure adequate coverage (1.0 mm or more from joint surface) at critical corrosion-prone areas while keeping overall thickness minimal for housing compatibility.
3Length of stationary object
If UV curable resin with low viscosity is used to reduce outer dimension, then insertability into connector housing is improved, but anti-corrosive performance may be compromised
Solution Approach 1:
The patent uses a specifically formulated UV curable resin composite containing photopolymerizable (meth)acrylate monomers and oligomers that provides both low viscosity (18,900 mPa·s or less) for thin coating application and sufficient anti-corrosive performance through the chemical composition and curing characteristics of the resin system.
Solution Approach 2:
The patent optimizes multiple parameters simultaneously: viscosity (18,900 mPa·s or less) for thin coating, elongation rate (60% or more after heat treatment) for durability, and functional group composition for adequate coverage and corrosion resistance. This multi-parameter optimization ensures both dimensional control and performance.
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 prevents corrosion of the joint while ensuring the sealing member can be inserted into existing connector housings, maintaining the original design and functionality without the need for housing redesign.
Implementation Method 1
an ultraviolet curable resin including 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 contains an ultraviolet curable resin including a polymerizable compound including at least one of a photopolymerizable (meth)acrylate monomer or a photopolymerizable (meth)acrylate oligomer. The anti-corrosive material has a viscosity of 18,900 mPa·s or less. The anti-corrosive material has an elongation rate of 60% or greater as a result of heating at 120° C. for 4,000 hours after curing.